Clutch Cable Install Issue - 911SC

[sigchuck]

Hi guys, I'm trying to get a new clutch cable in my 1983 911SC but cannot get it to seat on the tunnel tube. To further confuse things, I can't even get the old cable to seat on the tunnel tube.

The inside depth of the new cable fitting is around .6" and I can maybe get around 1/8" on the tube before it won't seat any further. I am assuming that this isn't as far as it should go, and it doesn't seem to matter if I put it in below the throttle bellcrank (incorrect, but more straight) or above the throttle bellcrank.

This is causing an issue when I attempt to hook the cable on the transmission. With the pedal side connected and set at 20mm depth I can't get enough give in the cable to get it hooked on the transmission/set in the adjustment channel on the transmission, even with a screwdriver holding the pedal at full extension.

If I set the cable in the adjustment channel with the forward nut as close to the car as possible, I don't have enough cable to hook.

If I pull the cable out of the adjustment channel to hook it, I can't get the threaded adjustment portion back in the channel.

If I unhook from the clevis, I'm fine on the transmission side, but the cable is too deep in the tunnel to hook on the pedal (while I've got it set to 20mm, I'm fairly certain the extra 2mm of range wouldn't make a difference).

I'm pretty certain the issue lies with not being able to seat the cable - if I could push it further forward, I would likely have enough of the threaded adjustment portion left to get it into the adjustment channel on the bottom of the transmission.

I came across one thread where a cable end had been left on a tunnel fitting and caused a similar issue, but I'm pretty sure that hasn't happened here based on a visual inspection. No idea how old the cable I took off was, but it's a Gemo (like the replacement I'm trying to install) and still has it's tunnel fitting. I'm fairly certain there's no interference with the throttle rod or the fuel lines. I'm also fairly certain it's not an issue of the cable binding in the tunnel as the old cable (that I also can't get on) snapped at the transmission end, so there's nothing that could go in the tunnel and bind.

Has anyone ever encountered this issue before? Any thoughts on how to proceed?

[boyt911sc]

Please post some pictures of your installation problem. That would help a lot to readers what actually is going with your cable installation. After re-reading your post several times, it was not clear I had a good understanding of the situation. Pictures would help. Thanks.

Tony

[sigchuck]

Good idea, Tony - my new cable won’t slide over the end of the firewall /tunnel tube. I can get it barely on (maybe 1/8”) and then it won’t go further. I am considering dropping the trans cross member and trying to use the fitting from the old cable (which I also cannot get to seat) as a die to try to resize the tube in the event it somehow got out of round. It looks a bit distorted.

[Dpmulvan]

Havnt done any transmission work have you? Is your transmission cable bracket on backwards?

[porschyard]

Originally Posted by sigchuck

Good idea, Tony - my new cable won’t slide over the end of the firewall /tunnel tube. I can get it barely on (maybe 1/8”) and then it won’t go further. I am considering dropping the trans cross member and trying to use the fitting from the old cable (which I also cannot get to seat) as a die to try to resize the tube in the event it somehow got out of round. It looks a bit distorted.

Looks like the tube is distorted, reinstall the cable and use a punch to drive the cable tension sleeve equally from both sides on to the tube until it bottoms out.

Richard

[porschyard]

Originally Posted by Dpmulvan

Havnt done any transmission work have you? Is your transmission cable bracket on backwards?

LOL The bracket will go on two different ways but I am pretty sure if he had it on backwards it would be pretty obvious. In the pics you will see the only two possible positions of installing the bracket. One is correct and the other is, well the other one is good for a laugh ��
Richard

[sigchuck]

No recent transmission work - the cable guide is mounted correctly.

I'm certain that I have a definite issue with the cable not seating completely (or barely any), so it seems that the easiest thing to do may be to make a "die" from the old cable fitting and pound it onto the tunnel tube in an attempt to reshape it. I'm still perplexed at how it went on previously though. Any ideas on how to accomplish this without removing the transmission cross member?

In thinking through the procedure for replacing the cable, the Omega spring is left in a tensioned position, correct? I'm not sure if that would help or hurt looping the cable on the clutch arm, but I recall having to take off tension when dropping the engine, so I was surprised to not see it mentioned in the cable replacement procedure.

[Dpmulvan]

Originally Posted by porschyard

LOL The bracket will go on two different ways but I am pretty sure if he had it on backwards it would be pretty obvious. In the pics you will see the only two possible positions of installing the bracket. One is correct and the other is, well the other one is good for a laugh ��
Richard

Its been done before believe it or not.

[Dpmulvan]

Originally Posted by porschyard

LOL The bracket will go on two different ways but I am pretty sure if he had it on backwards it would be pretty obvious. In the pics you will see the only two possible positions of installing the bracket. One is correct and the other is, well the other one is good for a laugh ��
Richard

https://forums.pelicanparts.com/porsche-911-technical-forum/1037053-clutch-cable-too-short-help.html

[pmax]

Originally Posted by Dpmulvan

https://forums.pelicanparts.com/porsche-911-technical-forum/1037053-clutch-cable-too-short-help.html

Apparently it was a pro who did that, let alone us amateurs.

[porschyard]

Originally Posted by Dpmulvan

https://forums.pelicanparts.com/porsche-911-technical-forum/1037053-clutch-cable-too-short-help.html

What amazes me is how long it took someone to suggest to look at the bracket. In the very first picture he showed of the bracket you can see it is on backwards.