Yet Another Broken Gear Cable

[G UK]

Driving back home today mid gear change I felt the sickeningly familiar feeling of the fore/aft gear cable letting go. I had a quick look at the side of the road and was surprised with where it has broken, knowing the drill I just manually moved the gear selector into third and drove home.

Here's some pictures, the end O-connector has pulled off of the end of the cable snapping it clean off!!! Has anybody seen them break here before?? It's certainly not one of the normal failures.

Any ideas on how to re-attach it without completely replacing the cable?

[dapinky]

My first thought here, although it probably wouldn't be super-strong, is to run a suitable size die down the rod bit of the cable to thread it and drill/tap the round bit - it may be too short to get enough adjustment to fit, but there may be a way of fitting a threaded section into the round bit and then using a female threaded tube to join the 2 bits????

[tb10]

Regards


John

[rip]

My first thought here, although it probably wouldn't be super-strong

Sounds like a temp fix only.
You've not had a lot of luck with gear cables, G.

[theelanman]

thems aint std cables........which version are they?

[G UK]

My first thought here, although it probably wouldn't be super-strong, is to run a suitable size die down the rod bit of the cable to thread it and drill/tap the round bit - it may be too short to get enough adjustment to fit, but there may be a way of fitting a threaded section into the round bit and then using a female threaded tube to join the 2 bits????

That was my first thought as well and would replicate how it was originally with the look of it. Would also give me an excuse to buy a new tap and die set as mine was stolen a couple of years ago.

You've not had a lot of luck with gear cables, G.

Something tells me i may be a little rough with gearchanges. I do seem to be good at finding new and original ways to break Elans.

thems aint std cables........which version are they?

I'm not sure, I thought they were S2s but can't remember how S2s our ABs are meant to look, its been a while since I had to deal with them on my last Elan. I'm sure Paul would know.

[bobbrown]

That looks like an AB cable to me and those ends are not very strong as there is very little material holding the end in place.

I did think about these a while ago when asked the question with regards to the ends but did not take it very far and you have just rekindled my thoughts.
Which were to replace the end with a rod end, as shown below

DSCF0250.JPG

These are what I use on the stainless steel cable and are far stronger than the cables themselves so you'll not break the end

It would mean tapping the rod M6 x 1 for 20mm and care will need to be taked to not mark the rod while you hold it, a bit couple of bits of aluminium in the vice should work but you will also need to make sure you do not cut the thread "drunk".
Can sort out a rod end modified to fit as they are in standard form threaded M8 if you want to give it a try let me know.

Bob

[bobbrown]

well that worked out quite well

1.JPG

2.JPG

[Rice crispy]

Bob,
would you be able to do that to my AB cables? would it make them feel like a set of yours? also would need to modify the short shift I asume

David

[bobbrown]

It is possible and no need to modify the short shift.
Not sure about the feel as there is a bit of slack in the AB cables when comparing them to the stainless steel ones, probaby due to the Stainless ones having a liner and little bushes on the rod, one thing it should help with is the self centering.
Now I know you are going to ask cost which is going to be £35.00 thats for 2 modified rod ends and the misalignment spacers etc to fit the cables to the gear selector at the gear box end.

Bob

[Rice crispy]

how much for fitting . I know a monkey that can assist but doesn't have a clue

[G UK]

The new connector came this morning, Thanks Bob.

Just removed the old cables, cleaned up the end and tried to thread it M6 x 1 but just couldn't get it started. I guess I need a stronger die than the cheap set I've got as I only succeeded in starting to strip the die

I can't post any pictures as my phone was stolen over the weekend

[bobbrown]

I think the rod is 1/4" (6.35mm) and I used a split die opened out to allow the thread to be cut and then closed it up to the correct size to finish it off, mind you I did do it in the lathe with a die box.

If you get stuck you could always send it here and I'll do it.


Bob

[G UK]

Got the cable sorted now, manage to do it at work.

I've got the cables threaded back through but now I'm having a bit of trouble getting everything bolted back in, I think I've got them twisted somewhere as I cant get either end seated properly so will have to have to have a look tomorrow after work to get them reassembled and tested.

Refitting the cables is always a of a job

[G UK]

Well its all back together and works

The crossgate cable however feels stiff and so the gearstick struggles to center itself, but at least it is driveable. It was a sod to get the mounting points lined up at both ends of the cables and needed more than a little encouragement to get everything bolted back down. It felt as if the cables were too long which I know isn't right so I think something is out of place but don't know where and how. I'll have to have a look at releasing the crossgate cable at the adjuster bracket and try and reposition it when I've got more time.

[HJ2]

Ah! The pleasures of scraped knuckles after a cable swap ... priceless!
Elegant Solution Bob! (as always)

[ccb056]

Well its all back together and works

The crossgate cable however feels stiff and so the gearstick struggles to center itself, but at least it is driveable. It was a sod to get the mounting points lined up at both ends of the cables and needed more than a little encouragement to get everything bolted back down. It felt as if the cables were too long which I know isn't right so I think something is out of place but don't know where and how. I'll have to have a look at releasing the crossgate cable at the adjuster bracket and try and reposition it when I've got more time.

Also had a similiar problem when replacing ours.
Turns out the bracket mating the cables to the transmission had to be modified a little.
Moving the knob became much easier when the cables had a straight shot from the bracket to their endpoint arms on the transmission.
With the unmodified bracket the cables had to turn slightly causing them to bind.