Removing and installing clutch cable (from 27.04.95) — VW

Removing

If clutch is a cause of complaint, then check function of clutch cable before removal => Page
30-5.
If no retaining strap is present then the adjusting mechanism must be tensioned with the retaining strap illustrated to enable it to be removed and installed. It is enclosed with new cables to tension the adjusting mechanism.
The ring (arrow) on retaining strap must be cut open.

Locate retaining strap ring above the protective sleeve (arrow).

Depress clutch pedal fully onto stop at least 5 times.
Move release lever approx. 10 mm, opposite to operating direction (arrow). The release lever must move freely.

The adjusting mechanism will be compressed.

Hook retaining strap tabs onto adjustment mechanism pins (arrows) (2nd mechanic) required.
Unhook clutch cable at gearbox operating lever.
Pull rubber buffer out of support on gearbox.

Unhook clutch cable on clutch pedal (arrow) =>from page
30-23.

Installing

(Clutch cable under tension)

Lubricate clutch cable attachment point at clutch pedal with MoS2 grease.
Push clutch cable through bulkhead and clip bellows in position.

Attach clutch cable to clutch pedal.
Press rubber buffer into support on gearbox.
Attach clutch cable to release lever.
Attach clutch cable into support bracket.
After installing clutch pedal remove retaining strap (arrows).
Check function of clutch cable =>Page
30-5.

Installing

(Clutch cable not under tension)

Lubricate clutch cable clutch pedal mounting point with MoS2 grease.
Push clutch cable through bulkhead.
Attach clutch cable to clutch pedal (arrow).

Attach retaining strap -A-
Pull end piece of cable in direction of arrow -1- and hold in this position, at the same time move the cable sleeve with the adjusting mechanism -B- to and fro several times, until it can be pressed together in direction of bulkhead (direction of arrow -2-).

Hook retaining strap tabs onto adjustment mechanism pins (arrows) (2nd mechanic) required.
Fit bellows into bulkhead.

Press rubber buffer into support on gearbox.

Attach clutch cable to release lever.
Attach clutch cable in support bracket.
After installing clutch pedal remove retaining strap (arrows).
Check function of clutch cable =>Page
30-5.

Notes:

The new clutch cable can also be installed in older vehicles.

The wire retainer for the new clutch cable must then also be fitted. It is secured to the battery console.
The battery console must be matched to the wire retainer -A-.
This means a 10 mm wide groove (arrow) 5 mm deep must be made.