#1: fitting clutch cable in gti 138 Author: scoop, Location: cairo,egyptPosted: Tue Aug 23, 2011 5:17 pm ---- hi, i have a peugeot 206 gti 2.0 with cable clutch system, i was pressing the clutch pedal to second gear and suddenly i found no clutch pedal under my foot and i was stuck on second gear, i when i reached home and stopped the car, i thought i cut the clutch wire, but it actually the clutch cable sled off the fork of the gearbox, but when i tried to refit the clutch cable to the gearbox fork, i found it too hard as the clutch cable is short and i have no idea how to stretch it or fit it back to the gearbox fork, any idea how to refit it back, i also have a bad clutch system anyway.. thanks in advance
#2: Re: fitting clutch cable in gti 138 Author: Seabook, Posted: Tue Aug 23, 2011 5:56 pm ---- we don't have clutch cable in a RHD gti, ours are hydraulic clutch system
#3: Re: fitting clutch cable in gti 138 Author: Deckchair5, Location: Bath UKPosted: Wed Aug 24, 2011 1:23 am ---- More and more people with the new type Peugeot clutch cable are going to find this happening to them that when the cable is released for maintenance etc then the self adjuster ratchets up to the maximum and then there is insufficient slack to even reattach the cable again to the clutch fork lever. Pulling on the clutch cable end makes no difference as you are just pulling against the clutch pedal securing hook. It's not the length of the cable that has altered of course, it's the self adjusting of the outer cable
The design is very different from the old original cables and their answer if there is not enough adjustment is "Buy a new cable". If there's too much slack then "Buy a new cable". Not ideal when the cables are £30 each but they reckon you are going to fit it once and forget it. Very stupid for designers to think people will never want to release the cable for other maintenance
I believe there is a way to back up the adjuster but you would need to simulate what the original fitting device does and that is to compress the adjuster springs on the outer cable so there is no tension, unhook the cable from the clutch pedal end and then pull the cable at the clutch fork end strongly to force self adjuster cable clamp further up the cable
You see this green and yellow fitting device on new cables? This compresses the adjuster spring for a one time fitting and then you remove it after the cable is fitted at both ends, it then takes up all the slack. If the cable isn't fitted at both ends then it just ratchets up to take out the slack and never backs up again
Here you can see the difference between the old type cables (top) and the new ones. Notice how I used two tie wraps to compress and hold the spring
Here is the crab like pincer that clamps onto the inner cable inside the self adjusting mechanism and it's this that prevents the cable being pulled out far enough to reach beyond the clutch lever
#4: Re: fitting clutch cable in gti 138 Author: tb206hdi, Location: DenmarkPosted: Thu Sep 15, 2011 3:35 am ---- On the one wehere you have tied the spring together - How do you then adjust the travel?
I'm having problems with the cable in my HDI since i run an uprated pressureplate I cannot use the original cables, so I'm wondering if I can modify the cable to act like a "normal" cable without the automatic adjustments.
#5: Re: fitting clutch cable in gti 138 Author: Deckchair5, Location: Bath UKPosted: Thu Sep 15, 2011 5:41 am ---- You detach it from the clutch pedal if it isn't already and then forcefully pull the inner cable through from the clutch lever end which will force the cable clamp along the inner cable up to the top again.
It's a really rubbish design. Fit once or throw away is their plan
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I cannot use the original cables, so I'm wondering if I can modify the cable to act like a "normal" cable without the automatic adjustments.
