Clutch Cable rubbing inside the outer cover

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AntrimMan

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I preface this post with a request for forgiveness. I do overthink. My dad does and I no doubt am him.
A brief history...
I purchased some universal cable kits from the premier supplier intending to learn as I go having not made up a cable before.
Life is not as simple as we all hope it to be.
The fabrication was no great big deal. I can solder as well as most can, I have an adequate stock rack and a small Logan engine lathe and a Bridgeport at home to conjure up ferrules and nipples and such. If anyone has used the universal kits in the maintenance of a Commando you know the shortcomings.
The present...
Does the cable really just rub like a bastard through the ferrule and into the outer cover as I see in the photo's?
Relaxed:
http://i1134.photobucket.com/albums/m60 ... axed_2.jpg
and Actuated:
http://i1134.photobucket.com/albums/m60 ... ated_1.jpg
This is an axial issue and is not the result of the clutch operating lever out of radial position by the PO.
Do we dust off the inboard end of the operation lever body to correct this?
Are there perhaps unidentified shims in there to be removed to alleviate this?
Bugger if there is supposed to be a conical seat in the clutch operating lever because I see only a simple taper.
In the photo's one can actually witness the bending of the cable when actuated.
The final photo is of the OE ferrule, this is worn badly IMO and sort of indicates I myself have not created the problem.
Ferrule:
http://i1134.photobucket.com/albums/m60 ... rule_3.jpg
Is this just the way it is? Seems rather unBritish actually, given the attitude. That's a friendly shot there boys.
All the best.
 
AntrimMan said:
I preface this post with a request for forgiveness. I do overthink. My dad does and I no doubt am him.
A brief history...
I purchased some universal cable kits from the premier supplier intending to learn as I go having not made up a cable before.
Life is not as simple as we all hope it to be.
The fabrication was no great big deal. I can solder as well as most can, I have an adequate stock rack and a small Logan engine lathe and a Bridgeport at home to conjure up ferrules and nipples and such. If anyone has used the universal kits in the maintenance of a Commando you know the shortcomings.
The present...
Does the cable really just rub like a bastard through the ferrule and into the outer cover as I see in the photo's?
Relaxed:
Clutch Cable rubbing inside the outer cover

and Actuated:
Clutch Cable rubbing inside the outer cover

This is an axial issue and is not the result of the clutch operating lever out of radial position by the PO.
Do we dust off the inboard end of the operation lever body to correct this?
Are there perhaps unidentified shims in there to be removed to alleviate this?
Bugger if there is supposed to be a conical seat in the clutch operating lever because I see only a simple taper.
In the photo's one can actually witness the bending of the cable when actuated.
The final photo is of the OE ferrule, this is worn badly IMO and sort of indicates I myself have not created the problem.
Ferrule:
Clutch Cable rubbing inside the outer cover

Is this just the way it is? Seems rather unBritish actually, given the attitude. That's a friendly shot there boys.
All the best.
Click to expand...
 
AntrimMan said:
the intracasies of photo posting continue to escape me although I have and continue to read the technical info.
Click to expand...


Copy and paste the photo's "IMG code" instead of the "Direct Link".

AntrimMan said:
Clutch Cable rubbing inside the outer cover


Clutch Cable rubbing inside the outer cover
Click to expand...

The photos show the cable is being forced out of alignment with the cable entry by the oil line which is a fairly common problem. I expect you will find an uneven wear recess around the cable entry under the ferrule as it would normally be a flat machined surface?
 
At the back of the battery box there is a hole which the clutch cable can go through and will allow proper alignment into the gearbox.

Clutch Cable rubbing inside the outer cover
 
pvisseriii said:
At the back of the battery box there is a hole which the clutch cable can go through and will allow proper alignment into the gearbox.

Clutch Cable rubbing inside the outer cover
Click to expand...

AntrimMan's is a Mk3, so it's got a different battery tray. The cable would also have to pass through the original airbox to be routed as it's shown in your photo.
 
L.A.B. said:
AntrimMan's is a Mk3, so it's got a different battery tray. The cable would also have to pass through the original airbox to be routed as it's shown in your photo.
Click to expand...

Damn, I could have sworn thats what it was for. Lines up just perfect.
 
let me try this img code...

there is indeed some damage to the ferrule abutment as L.A.B envisioned:
Clutch Cable rubbing inside the outer cover


this is the difference in the ferrules:
Clutch Cable rubbing inside the outer cover


I made the one on the left, it is a much closer slip fit into the hole with much longer engagement than the OE.
The OE (I think) ferrule actually swims and rocks in the cover hole due to the clearance and shorter engagement. My question now is is this looseness intentional to allow some pseudo alignment with the actuating lever?

The ferrule I made is relieved inside to provide clearance for the cable as it moves through the arc of actuation but this is a mute point if the damn thing is not ever in line.
Clutch Cable rubbing inside the outer cover


The L.A.B. theory of misalignment due to oil line interference is not proven. The ferrule is way to snug in the cover hole to be forced over axis.
Thanks for the ideas so far.
All the best.
 
AntrimMan said:
The L.A.B. theory of misalignment due to oil line interference is not proven. The ferrule is way to snug in the cover hole to be forced over axis.
Click to expand...

Well...it would be... now you have made up a close fitting ferrule! As can be seen from the wear pattern in the photo, the original ferrule has been forced outwards sufficiently to wear an indentation around the outside edge of the abutment hole (my own Mk3's case has the same wear pattern around the abutment), however I agree that the angle of the cable abutment drilling is not perhaps as good as it could be, but yours does seem to be rather worse than usual. The lower ferrule of my Mk3's cable does not show any evidence of the inner cable being pulled over to one side as yours has. My Mk3 doesn't have the black airbox so the cable routing is better but it still held slightly off its natural line by the return oil pipe.

Are you certain that the lifter arm is accurately aligned with the abutment?
 
L.A.B. said:
Are you certain that the lifter arm is accurately aligned with the abutment?
Click to expand...
Well it may be radially but a skosh from perfect.
The major misalignment is of the cover ferrule hole being too inboard for the location of the forked nipple connection on the actuator or vice-versa.
This is just the nature of the beast as far as I can tell. I do not know for certain if anyone has ever had this cover off. The screw head slots do provoke suspicion however.
I will attempt to correct this misalignment as much as practical at some point but since it has been going alright prior to my intervention I would expect it to continue.
Probably I will dust some off the end of the operation lever body to enhance alignment. Would be nice to have a spherical swivel in there too to keep the cable tension in mostly one plane. Maybe if the cover hole was enlarged to accept nesting cammed inserts which could be rotated independently of each other to align in x & y just dreams really, that would alter the covers appearance and I will resist any such change to the appearance.
So, thanks for all the advice, no desperation just yet. I do plan to carry the spare cable just in case a revolting development should materialize.
All the best.
 
Ah, so the problem is that you made a part that is too precise and doesn't allow for any tolerances?

Remember that the cable may change it's angle due to the different tension during the clutch operation. This was probably accommodated by allowing the ferrel to move about in the hole.
 
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