Hi polo peoples. Hope you're all safe and well. 

Hopefully just a quick one today. 

Looking for recommendations for clutch cable for stock 1983 breadvan? Had a Pagid one from euro as my last one. Still works, just a little crunchy when my foot gets down towards the floor. 

Does anyone lube their cables at all? 

Thanks for stopping by and for any guidance you can give. 

Hey guys. Had to take kids to the dentist this morning. All god till i went to park up. Went to reverse to straighten up, clutch pedal was loose and floppy. Turns out the cable had come off the end. I put it back on, adjusted best i could with two kids rampaging in the back. When i drove off, the engine kept revving high but had no power. Like the clutch wasn't engaging. Got them to school, another quick adjustment and managed to get home. I've now got home and the release arm will not move at all. I've taken the cable off the pedal end but can't get it off the release arm as it will not move in any direction. The cable is as loose as i can get it but won't come off. Does that sound like a dead clutch by any chance?

Thanks for stopping by.

by hand ?  i think theyre fairly tough to move anyway?

 

arms can get tight ...gearbox out job to clean and regrease it though

After some serious, olympic standard jiggling, i managed to take the cable off the release arm. Took the whole thing off, checked it out, looked fine so i refitted it. Seems okay at the moment. Test drive, the revs were way higher than they should be at high revs in 3rd and 4th. I'm hoping that'll just take an adjustment to sort out. The free play in the pedal is within parameters i have in the Haynes, no grinding in any gears, just the revs at high revs needs sorting. 

 

I did adjust it by hand, best i could at the time. Only had one mini socket set on me and that was no use at all.

Had to hold the bolt between the release arm and the cable mount with my fingers and try to turn the plastic half circle bolt thingy with the other hand. Much easier with the spanners at home.

 

That little crunchy feeling at the very end of the pedal travel has now gone and it feels just a little lighter too. 

Anyhoo, i'll give it another tweak when it stops raining and see how that goes. 

Thanks for stopping by. 

dont drive it far with it slipping ...you will kill it if its not already dead 

 

not the self adjusting cable type then?

The revs up from normal at any particular road speed sounds like clutch slip.

 

Any smell of burning?

 

if so the clutch linings are at risk of being fried.

Not self adjusting.

Think i have it about right though. 

I've adjusted again, just a couple of turns on the plastic half circle bolt and it seems much better. Right up the rev range in 3rd and 4th, up to about 50mph so far. No slippage as yet. Also seems a little lighter than before and no little crunchy bit at the end of the pedal travel. It is the same cable too. 

 

No burning smell. Well, none that wasn't there before anyway. But that isn't gearbox related.

 

I've had what i thought was clutch slip a couple of times in the last year. Was real slight, only just noticed it. Was always in high revs in 3rd gear. Revs would climb a little but the engine/car speed wouldn't match. Would catch up real quickly but i'm sure it was there.

 

I'm guessing as this has happened, and i did drive it while it was slipping today, that i should be prepared for something potentially bad to happen? At the very least, should i be looking at new clutch in the very near future?

 

Could be good opportunity to try the 5 speed conversion that i've wanted for ages? From what i've read, i just need a 5 speed box and arb from a m2f polo? I do already have arb blocks in place though as i'm running H&R cup kit. 

 

Thanks for stoppin by dudes. 

Seemed okay this morning. The only thing i have noticed is that there is a slight lag pulling away compared to how it normally is. Had no slipping at all but i didn't really get over 45mph. 

If it’s adjusted correctly it could be your clutch is worn out anyway, and down to the rivets on the clutch plate friction linings.

 

They usually wear out the clutch cover side first, putting big score marks in the pressure plate.If it wears out the flywheel side too then it’ll also score that,, leading to needing a new flywheel.

 

Unfortunately the only sure way of knowing is taking it all apart.

Edited 25 May, 20215 yr by mk2tastic

I've had it 3.5 years and not had the clutch done in that time, been used as daily for fair chunk of that time and done fair few miles. Even during lockdown. Lent it to key worker mate.

 

It did come with some paperwork so i'll have a rummage through that, see if there are any receipts for clutch or even gearbox work. If not, i'll make that the next thing to tackle.

Thanks very much.

Gone through the paperwork i have, which is extensive! Have original service schedule, including the registration form! Schedule is missing a couple of stamps but only a couple. 

Nothing anywhere in the paperwork or receipts to say that the clutch has ever been touched. At all. Fuel tank, dizzy, cv boots, bearings, oil changes, wiper blades, anti freeze, even down to receipts for the smoked indicator lenses are tucked in there! But nothing about clutch. 

I've spoken to the garage i normally take it to, they say as long as it's running normally at this point, which it is, then leave it alone, if it ain't broke....

I also called a gearbox specialist in Exeter who i've never dealt with, just for a second/objective opinion on the same story. They said the same thing. Except they said not to call them because they wouldn't work on anything that old, but leaving it alone as it's working is sensible at this point. Both places said there would be signs if i were to have issues. 

I do have breakdown cover so if anything does happen. 

 

So how many miles has it done on that clutch? 

Polo is light so you should be able to comfortably exceed 100,000 if driven gently.

You might get 10% more after your last adjustment with same driving style and loads (and you've not adjusted cable every 10,000).

 

If going 5 speed you could perhaps also switch to 190mm clutch from 180mm. I suspect with same flywheel if not scored.

 

You now know the symptom of revs rising with no change in speed and the pedal movement becomes limited.

 

You can also do a stall test to confirm, where you try to pull off against the handbrake in high gear on firm flat ground. If the engine does not stall (without moving the car) before pedal fully raised the clutch is slipping. I'd do that test before attempting a long journey.

This is what is on the clock. That doesn't seem like very much considering it was registered in 1983! 

I pulled away in 2nd gear earlier today just fine. Haven't tried 3rd or 4th yet. 

 

Probly good job i didn't though as the cable went loose again on the way home from work tonight. Didn't feel right under my foot so i reached down with my hand and it was loose. Like, a good half an inch of just loose. 

I read the Haynes manual and followed it best i can but somethin i'm doin isn't right. Unless i tighten it stupidly tight, i can't get it to stop bein so loose. If i go into the engine bay and pull the cable housing, it's fine until i put my foot on the pedal again, and it goes all floppy again. 

I've got it super tight at the moment, like, almost no freeplay at the pedal, and that seems to work, but i know that isn't how it's supposed to be. 

 

I found a different cable that i'm gonna fit. If the same thing happens, which i'm pretty sure it will, then it isn't the cable, it's me fitting it wrong. I just can't figure out what it is i'm doing wrong yet. But i will figure it out.

Think it's sorted!!! Clutch cable inner housing was frayed at the pedal end. Think that was catching and stopping the cable from staying in place on the pedal. Took it off, trimmed that back just a touch and it's fine. Silky smooth and actually a little lighter to use. 

I still have another on the way so will keep that in the car to fit if this one has any more issues.

Well found and fixed um, worked around.

 

VW clearly did not expect the car to do more than 99999.9 miles. 

Or it saved VDO a few pennies to have one less digit per speedo.

I wonder how many times it has gone round. 

Most cars do about 8000 per year so could be 269,016?

You'll have to find any receipts with miles on to spot the rock around the clock events.

 

Try the stall test with new cable. I changed my clutch cable at about 210,000 miles

when clutch was slipping about 110,000 after I fitted a 5 speed gearbox with new clutch friction disc.

 

I'd forgotten those I II III markings on the speedo for gear maximums when there's no rev counter. 

Edited 28 May, 20215 yr by dvderlm

Dude, it's silky smoov at the moment so i'm leavin it the fudge alone!!!!

As soon as the new cable arrives, it's going in the boot, so it's ready for when i need to change it over.

 

I will try the stall test. I was gonna try and pull away in 2nd again earlier but totally forgot about it. 

 

Checked regularly on the drive home tonight, pedal seemed much more consistent, didn't move or flop around. No slipping that i noticed. Didn't get it up over 45mph. May try again in the morning. 

 

I have a fair few mot certificates so may be able to work out when it ticked over.

Great, if you can replace cable at side of road. Sounded like you might have taken it out ("took it off") and refitted, rather than just unhooked at pedal. I can't because on my car there's an obstructing Stab-o-shock steering damper that makes pulling old cable out through bulkhead a right hassle.

 

When doing the stall test you might want 3rd or 4th and a fair few revs due to the awesome torque of Polo engine in 2nd. It's simulating the high load and revs.

 

"If it ain't broke don't fix it" is a good approach to life.

Nowadays I err a bit more towards "trust, but monitor".

 

 

FINALLY got around to doing stall test. 3rd gear with handbrake on, engine cut out just as i got to top of clutch pedal travel. 4th gear and it actually moved a little before cutting out. Again, right near the end of the pedal travel. The bite point is still pretty high though so possibly why it took that long to cut out. 

I'm going to take the Pagid one off that i trimmed down and replace it with the Borg and Beck one in the boot. See if that makes a difference. 

Thanks dudes.

Edited 15 June, 20215 yr by Eviljohn
Wrong info

Did stall test again today. As above, handbrake on, engine warmed up, didn't cut out in 3rd or 4th. Actually went to pull away so i'm guessing it's new clutch o'clock! Good times.

So i'm now looking for new clutch kit. Am i right in thinking the early, (early 1983,) breadies use a 180mm clutch kit? Like this one perhaps.....

https://www.amazon.co.uk/BORG-BECK-HK6265-Clutch-Sets/dp/B00GJQY3IE/ref=asc_df_B00GJQY3IE/?tag=googshopuk-21&linkCode=df0&hvadid=231920316197&hvpos=&hvnetw=g&hvrand=10080380299949915161&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=9073563&hvtargid=pla-562595425808&psc=1&th=1&psc=1

 

I remember when getting my clutch done being told to get the guide for the thrust bearing, had to order from VW, was around £3 and they thought I was mad, but when the clutch came out the guide was in bits along with the thrust bearing. Not sure if it was an issue with the early cars too.

13 minutes ago, Jim1500 said:

I remember when getting my clutch done being told to get the guide for the thrust bearing, had to order from VW, was around £3 and they thought I was mad, but when the clutch came out the guide was in bits along with the thrust bearing. Not sure if it was an issue with the early cars too.

 

084 141 181A  4 speed box

085 141 181    5 speed box

 

It's always a good practice to replace the guide sleeve when fitting a new clutch, as murphy's law says it will probably fail 6 months after you've changed the clutch and then you've to strip it all down again to replace the sleeve. 

Sweet! I just jumped on one of those bad boys. Thanks for that!

ECP list three different clutch kits for the mighty mk2 polo, based on my reg number, ranging from a few ££'s to many ££££'s. Doesn't list the size as far as i can see but i am using a mobile to rummage in the interwebs. Can i trust those scamps at ECP or should i rummage some more for one that is listed with more info? 

I only checked ECP as i don't have a GSF locally. If that 180mm Borg and Beck one, or similar, will fit for shizzle, i'll snap one up. 

Is anyone aware of any carboard clutch kits that i should absolutely avoid? Any that anyone recommends? Not something i want to get done yearly. 

Thanks peoples. Keep safe.

Edited 16 June, 20215 yr by Eviljohn
Wrong info

i dont trust them one bit...look it up yourself online 

 

go for a sach or luk if keeping the car , can often find a badly listed bargain on ebay

Okay cool. I did find Sachs, also Quinton Hazell and DTC.