CorollaNut68 Posted January 25, 2015 Report Posted January 25, 2015 (edited) I have gotten a couple of different versions when ordering new clutch cables. Some have been bare cable, some have had a plastic coating on the cable and all have been too long because I think they were actually for later models. I made a spacer for the longer ones but would rather not have to use it. It's also getting hard to find them at all over here. So...as long as you still have a good sheath and the adjusting rings are useable.... This is how I make my own cables. I used a slightly thicker cable than what came stock, about as thick as stock plus the coating but still fits in the pulleys nicely. Getting the length right is important because just a little difference in the cable makes a big difference in the pedal and adjust-ability. This is where your patience will come into play. I would give you length but I didn't measure, I went by sight, sorry. (Edit: I forgot the right hand version doesn't have the pulleys and such a long cable so my measurements wouldn't help for the right hand drive anyway.) I bought 11.5 feet to make two cables and there will be a few inches left. You need a bit to make the loops on the end so you can't quite measure it like the stock ones with the molded ends. I take my old cable to my local hardware store so I can match sizes and buy a length of cable, two ferrules and a couple of wire thimbles. You will be cutting one of the ferrules in half and just using bits of the thimble (that's what they are called, don't know why). Cable Hammer Punch Wire cutter Needlenose (not pictured) Vise Grips (or actual vise if you have one) Hacksaw Ferrules (2) Thimble (1) File (not pictured) The curved thing is the thimble, the other two are ferrules. I start with the smaller end that goes to the pedal. First cut one ferrule in half. There isn't room for a whole one as you'll see. Then slip it on the cable and pull it to about as tight a turn as you can. I happen to have a spare set of pedals which makes it easier to make sure it fits. Needs a little tighter than that so once it's in there you have full travel of the pulley and no binds or bumps. Try to make sure it's good before you punch the ferrule tight. After cutting a small piece of the thimble to fit. This rides on the pedal and keeps it from sawing on the cable. Squeeze it up in there tight and centered with the needlenose. While holding it in place, crimp it on with another set of pliers. You get something like this. There seems to be slightly less space in my car than shows here when all is in place. Next make sure the end will fit through the hole in the firewall. After punching it, the sides will swell a bit. rather than hammering the sides which may loosen the grip, use a file or sandpaper and smooth the edges till it will slip in the hole. With that end done, go ahead and cut the old cable and slip it out of the sheath. This one had worked fine until I got some PB Blaster on it while trying to get my pedal to stop squeaking. Do not get PB Blaster on it and you should get several years out of it. You can lube the cable, just don't get anything on the ferrules. Anyway...Slip the new cable into the sheath, make sure it's the right way round. The end you just made goes to the pedal. Then you make your loop for the end that goes on the tranny. This too will need to be tight but not quite as much. I try it in the car before punching the last end. Hook it to the pedal like you're installing it but you're just making sure it will reach, not too long or too short. the only wiggle room you have is in the adjusting clip at the firewall. Make sure it reaches ok, try not to let the end pop out while fiddling with it since it's not punched yet. When you're reasonably sure it's good, go ahead and punch it and try it out. It will be tight getting through the bracket hole in the tranny too but it will fit if it's right. It's not expensive or terribly hard to do, there may be some cussing moments and you may get it too short or long on your first try but it's better than nothing and only takes about a half hour. I got enough stuff to do 2 of them for about $6.50 My better attempts have lasted years, they tend to get weak at the pedal if you get the loop too tight Edited February 16, 2015 by CorollaNut68 Quote
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