clutch cable snapped a few months ago and then the same thing happened a couple of weeks ago (soft pedal - the warning shot before it breaks completely) I took it out and it had worn inside the black conduit at the back (I had put a new one on when I changed it a few months ago) When I did this I didn't have the seals around each end of the conduit. It broke fairly quickly though so I am wondering why this might have happened? bits of dirt getting inside the conduit and gradually wearing it through? I have put a new cable in now which should buy me another 6 months but I'd prefer to solve the problem than keep buying new cables!
Yep all well greased and yeah on one of the conduit ends. I gonna feeling it's the missing seals on the conduit doing it
I dont know about any seals on the conduit? I had 2 clutch cables go on me within 18 months- well start to go! I copper greased all of it and put extra in the conduit. Ensure the edges of the conduit are not cut in at the ends - where lazy previous owners have not greased and the cable has been sawing into the tube? I do however think the quality of steel used in cables today is very poor anyway! Top Tip - KEEP A SPARE in the van and 1 at home!
I put a new cable and conduit on last year, the old one snapped gradually inside the conduit, I adjusted it a couple of times before it finally went. I forgot to put the rubber seal on so I cut it put it on and zip tied it, but it doesn't stay in place, so I dont think it is of significant importance. i put loads of moly grease on the bit in the tube and its been fine, much smoother than it was before. I did wonder what would happen if you accidentally twisted the cable while doing it up, I assumed that it would stress some stands (outer?) more than others and they would go first, is that possible or were you just unlucky with a crap cable?
Check the angle of how the conduit is sitting. It should be a gentle curve at the bottom and not a sharp curve if that makes sense.
Is the conduit set so it has some deflection. It shouldn't run in a straight line from mount to mount. Should be curved like a shallow S. The cable needs to exit the solid conduit in the same plane as it and then curve up in the flexi and the same for exiting to the clutch lever A few mates had your problem and in each case it was lack of deflection. To prove that theory wrong, mines more in the shape of a C and have only had 1 ping. If folk are missing the collars or seals as you called them, the flexi conduit can be too short to get enough deflection.
To add to previous post. If the path of the cable resembles the shape of a shallow Z that's Ping A Go Go. The cable ll be changing direction over a too small a radius, putting far too much strain on it. This applies to both the exit from the chassis mounted solid conduit and the gearbox mounted one.
Thanks it all makes sense. I think mine was a smooth S which is why I am confused, the clutch cable I got in now did look a bit thicker but that isn't stopping the source of the problem. I'll post a picture of the conduit in situ when I get my bus back this week. Thanks for the help
