Self-Adjusting Clutch Cable - Revised
90vw06Subject: Revised self-adjusting clutch cable
Model(s): Jetta 1989-90 m.y.
Group: 30
Number: 90-02
Date: August 31, 1990
Beginning in 1989 m.y., self-adjusting clutch cables were revised to include a sheath (arrow). The self-adjusting cable mechanism cannot be disassembled.
The revised clutch cable with sheath cannot be compressed with 3151 during removal/installation as with previous self-adjusting clutch cables. When replacing a clutch cable, the strap that is supplied with the new cable can be left on after installation for future use.
If a production-installed cable needs to be removed/installed, a retaining strap must be cut from a replacement cable and used to compress the spring.
Self-adjusting clutch cable retaining strap, removing
^ carefully cut open strap at center eye (arrow)
Self-adjusting clutch cable, checking/ removing/installing
Checking
Note
The clutch cable adjuster mechanism must be undamaged.
^ fully depress clutch pedal five times
^ move clutch release lever on transmission down (arrow) approx. 10 mm (3/8 in.)
^ release lever must move freely
Removing
^ fully depress clutch pedal several times
^ install retaining strap in position above boot (arrow 1)
^ compress adjuster mechanism
^ hook eyes of strap to pins on adjuster mechanism (arrow 2)
^ remove securing parts on release lever
^ remove cable eye from clutch pedal and remove clutch cable from vehicle
^ carefully remove retaining strap from cable
Note
If the adjuster mechanism cannot be compressed, the clutch cable must be replaced. The cable will have to be destroyed to remove it from the vehicle.
Installing
^ grease clutch cable eye on pedal end with MoS2 grease
^ push cable through body panel and hook over clutch pedal end
CAUTION
DO NOT kink clutch cable. If the cable is kinked, the adjuster mechanism cannot function properly
Note
A second technician is required to assist in installing the retaining strap.
^ install retaining strap A to cable above boot (do not hook strap over pins yet)
^ pull cable end in direction of arrow 1, hold adjuster mechanism B and move cable end back and forth a few times until spring can be compressed and held in that position
^ hook eyes of strap to pins C on adjuster
^ guide end of cable through mounting on transmission and clutch release lever
^ install fastening parts to cable end
^ remove retaining strap or ty-wrap ends of strap out of way if cable is new