Clutch Cable Tube Repair (In Tunnel)

If your VW sedan clutch chatters and or makes a strange noise and you checked everything out. You may have a broken clutch tube bracket in the middle of the tunnel. Here is how I repaired mine.

[@mukashi911]

THANK YOU for this video!! My 70 is doing the very same thing and making the SAME noise. Now after watching this I feel better about what I need to do to fix the problem. Keep the good videos coming!!

[@peterduxbury927]

I still own a '71 Beetle that developed this same problem (Bowden Tube Broke away from the Tunnel) in about 2004. My "Fix" was a lot different, but it silenced those Squeaky mice forever. I shone a Torch down (without cutting the Tunnel), and then I pinpointed the location where the Tube had broken away. I then marked / drilled a single 3mm hole in the Tunnel. I carefully lowered a piece of rubber - which was about 12mm thick. With the rubber piece wedged between the Bowden Tube and the Tunnel, I then locked the rubber cushioning piece in place - by use of a single Self - Tapping Screw. The Screw went through the 3mm drilled hole. Yes, it was a very fiddly job, and I figured that the most natural "run" of that Tube was when it had broken away. I figured that I would have needed a large hole to re-weld, only for the Tube to break away again later. With the Cushioning Rubber inserted, the Tube is now in its most 'natural' position. 20 years of daily driving, it has been just perfect since doing this. I am writing this, to help other Beetle Owners - who may not have a Stick / MIG Welder at hand. My idea really works!! Greetings from Australia.

[@TheEZGZ]

Thanks so much for sharing your experience. Can't argue with time tested solutions. Thumbs up mate!

[@peterduxbury927]

@@TheEZGZThanks for your reply. I forgot to add, that the rubber piece that was inserted into place, was also "scalloped" with a half circle, that matched the Bowden Tube Diameter. This allows the Tube to seat comfortably within the new Rubber Block used. Obviously, the rubber thickness needs to be sufficient - to hold the Broken Tab - away from the Tunnel. The Rubber Block was also designed to sit directly on the Tunnel Floor, with the "scallop" section of the rubber at its correct height from the floor. I mention the word "scallop" - but this was a drilled hole in the rubber at the same Tube Diameter, and really close to the edge of the rubber piece. In this way, you simply cut a rubber section (along the length of your drill-hole) away. Your Bowden Tube then becomes a SNAP FIT into your new rubber section. I am writing all of this, so that you may (perhaps) make another You Tube video at some later date. This idea really works, and is less invasive, preserves the structural integrity of your Beetle. At the time when I faced this problem, I thought that I was the only one on the Planet with the Broken - away Tube! I had to find a simple solution. Thanks for your appreciation.

[@bigwadventures7061]

Nice job. When you got a 45 year old car things happen. But it's also the reason why I love these cars, you have to care for it and it rewards you with a therapy ride.

[@johnmartin5153]

Thanks GZ!! My 71 super has been doin this for years, driving me crazy. Glad to see a solution

[@TheEZGZ]

it's a PITA to fix but worth it.

[@johnmartin5153]

@@TheEZGZ yep I have to do it , that noise is driving me crazy Sounds like chewbacca getting kicked in the nuts everytime I shift 🙃😂🙃. Haha. Take care GZ

[@jevchance]

Pretty intimidating job you made look easy. Nice work.

[@rheidtech]

i know man....I've heard that alot and didn't have a clue what it was. killer vid.

[@geargriden19]

Good repair EzGz! Have a good'nnn

[@TheEZGZ]

+geargriden19 Now I can put the 2110 in the car and not worry about braking that clutch tube

[@RustyGlovebox]

Very good point, I can see how that would cause some problems with the clutch assembly adjustment. Thanks GZ

[@TheEZGZ]

+Rusty “rustyglovebox” Glovebox One of those PITA jobs that I just kept putting off. Glad to have it done.

[@TheEZGZ]

3 is correct. You also have the option of a sandrail hydraulic clutch operating system. Might take some thinking to get a peddle assembly to fit but it would sure make it easy running the line and the slave cylinder on the tranny side

[@vw64manyrd]

Like fingernails on a chalkboard...Good fix! Thanks for showing!

[@brenton-lucas]

Wow top of the class A+,thanks for sharing.

[@TheEZGZ]

Thank You Sir

[@bigrodney1453]

Would this cause a clutch to not disengage all the way and drag???

[@MidwestMotoRider]

Nice easy fix.. Thanks!

[@TheEZGZ]

+MidwestMotoRider Thanks for your support

[@cutworm59]

That is about the slickest repair I have ever seen! You amaze me bubba. Wow! Did you use them heads that had the cooling fins cast closed?

[@TheEZGZ]

+cutworm59 Thanks. I didn't use them on this build but I do have plans for them in the near future. Stay tunned.....

[@spanermantim]

Good one. I thought you just needed to feed the mice to stop them squeaking.

[@edwinhsingmaster9135]

The hole in the Boden tube (on the front) is for a needle grease point. A well greased cable greatly reduced the lateral force on the tube, as its not a straight shot.

[@TheEZGZ]

Good to know. The bowden tube design was to keep grandma from feeling things in her foot and give it a softer action when she wore slippers. :-)

[@edwinhsingmaster9135]

Good idea to add a weld to Boden end of cable tube,, it's probably cracked due to center support weld failure. Just don't set the place on fire!

[@JayDubCustoms]

EZ, any idea how many total welds there are holding that tube in? Maybe 3, one at each end and then one at that bracket you welded? I'm guessing. What say you? I need a tube for an autostick swap to a manual I'm doing. Thanks!

[@TheEZGZ]

3 is the factory number. If you can figure out the pedal side you could also do hydraulic

[@KevinPerez-ct9jn]

Thanks 😊

[@TheEZGZ]

Welcome 😊

[@bigrodney1453]

I don’t have the noise, but I’ve checked everything else from the clutch to the pressure plate to the throw out bearing, pedal assembly and the cable!! And everything in between

[@TheEZGZ]

Have you checked the hook on the clutch arm of your peddle assembly? After years of use the groove can get real deep and shorten the throw. It is not a fun job but most pedal assembly bearing could use a good clean and lube along with some fresh paint on the floor where it gets rusty and full of dirt.

[@bigrodney1453]

TheEZGZ Everything looked ok to me, I really don’t have anything to compare the clutch pedal hook to, but to me it looked fine. Originally I thought it was actual clutch disk , but it looked pretty new when I pulled it. Then I thought freying cable, pulled that an it looks solid to! Is there a way I can send you some pics for your opinion? I’ve watched your videos, looks like you have years of knowledge.

[@wtbm123]

Cool

[@Smarty1171]

Do you think the tunnel is weakened now? I do. I have seen tunnels crack where the handbrake heater tube levers are from actually bajaing Myself. I would have made a much smaller hole 3/4 of an inch at most maybe smaller and put an insulating sheath taped on the welding rod so it wouldn't arc on the sides. Ala the operation game we played as children.

[@TheEZGZ]

I have had to do it to 3 different cars and never had a problem. I doubt you have seen cracks. You can't work threw a 3/4 inch hole. If it bothers you make the hole do the repair and weld the peace back in. I never played the operation game. I was ridding my bike. hehehe

[@Smarty1171]

TheEZGZ that's ok. You can doubt all you want. I just welded the cracks a couple days ago. Maybe you can't work through a 3/4 hole. But I can.

[@mukashi911]

What size hole did you cut? Also how far down do you have to cut to avoid hitting brake cables?

[@TheEZGZ]

About 4 inches and the rest you can judge by the video. They are all the same in all years of the sedan model

[@mukashi911]

That is what I have. Thank You again!! I would love to share my pictures with you when I cut it if there is a way.

[@monchy25]

I need to do this how do I cut the hole what size? How do I ask for it? The bracket that holds the tube Is it on the same spot on a ‘66 bug?

[@TheEZGZ]

I just used a 3 inch hole saw. Hopefully you can weld the factory bracket again and then add a peace to support it. Be safe. One of those tubes is the fuel line from the gas tank. I've had to do this on several cars and I don't fill in the hole. Doesn't seem to effect the structure and carpet covers it.

[@monchy25]

@@TheEZGZ thank you 🙏🏽

[@duggy788]

being listening to that for ages , i thought it was something to do with the end of the clutch cable link, little things like that are so annoying i find.

[@TheEZGZ]

+duggy788 It was only doing it on the kennedy pressure plates but it about drove me crazy on this trip. Glad to have it done. Even added another leg after I posted the vid to make sure.

[@michaelknight2897]

I cant find the size of the stock tube. Do you know the size of the stock tube?

[@TheEZGZ]

No! Just as long as it's big enough to fit the cable ends..... I've always been able to repair the old one while in the tunnel.

[@littlepippin8445]

I changed the clutch cable on my bettle - nearly killed me.... it's RHD so access is crap, and the previous owner had welded the hook plate closed so you couldn't slip the cable eye off without grinding it off...

[@TheEZGZ]

I don' t care what anybody say's if your working alone the clutch cable can be a Beech hehehe I use a weak bungie cord at the tranny end so it doesn't slip off the hook while your finagling with the peddle assembly. I have been needing to replace the hook and shaft on my 66 for years. The hook broke so I welded it back together and smoothed it like stock ( I thought) The problem is I made the groove to deep (1/8 inch?) It makes letting the clutch out like a hair trigger even when you have it adjusted correctly at the bell housing. If I use an engine with lightened flywheel I sometimes kill it leaving stop signs. I keep saying I will do it tomorrow but I never think of it. LOL Note to self .......

[@JoelPit]

Why did I figure you had this fix. At this point it seams your my VW guru. Next I'm I'm in Oklahoma we need to meet. Little Sahara sounds fun. Do you need an apprentice. Check out my skoolie tow vehicle at traveling with JRP here on youtube

[@TheEZGZ]

Glad I could help