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Clutch cable replacement

Discussion in 'Problems, Fixes, Tips...' started by Jacques84, Aug 29, 2014.

  1. Jacques84

    Jacques84 Copenworld Newbie

    Joined:
    Aug 29, 2014
    Location:
    South Africa
    Car(s):
    2010 Daihatsu Copen model L881
    HI all

    Has anyone replace a lutch cable on the copens themselves? I am really battling. Can't seem to get the cable out. The aircon unit behind he dash is in the way.

    Please help?
    Jacques
     
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  2. CA49000

    CA49000 Copenworld Member

    Joined:
    Oct 22, 2011
    Location:
    Cape Town, South Africa
    Car(s):
    '00 Honda Ferio SiR (Track Car)
    '06 Daihatsu Copen (Daily)
    '10 Daihatsu Sirion 1.5 Sport (Family Car)
    did you come right boet?
    Where in South Africa are you situated?
     
    buz graham likes this.
  3. tictac

    tictac Copenworld Member

    Joined:
    Oct 8, 2013
    Location:
    Melbourne, Australia
    Car(s):
    Copen 2004
    Prius 2006
    Hello fellow Copenistas, thought I would enlighten you as to a recent maintenance adventure. For a while the clutch seemed heavier than it really should be, indeed it seemed to stiffen up during long drives, so after a bit of fiddling investigation I decided it was most likely the clutch cable rather than the clutch itself.

    After a replacement clutch cable (part number 31340-97403) arrived – yes, easy enough to order here in Australia but a couple weeks wait while it came from Japan – I then figured, can’t be too hard to fit. Just like a motor bike clutch cable only thicker. A read of the manual – thanks to Copenworld for having them on the website – revealed step 3-1-2 “OPERATION BEFORE REMOVAL - 1. Remove the instrument panel assembly. Refer to Page I2-221.” That seemed a bit extreme, so I decided to have a crack at it without removing the dash.

    A few hours later with drivers seat removed and me upside down in the foot well and a bit frustrated by lack of access, I bit the bullet and decided to remove the dash. A few hours later after that (steering wheel off, airbags removed with battery disconnected, dash out) I had the cable replaced, although it was still difficult to get the old one out and the new one installed given the small fitment hole in the firewall right behind the aircon / heater fan unit which would not move much out of the way due to the structural bracing tubing running across the car behind the dash. Ouch. A trick to getting the cable through the firewall hole was to unscrew the plastic adjusting nut all the way off the end of the cable outer thread, thus providing more play / freedom to enable the cable outer to come through the hole then using some sideways angle to get the adjusting nut through the hole separately (bend the inner cable to do this). Install new cable using the same approach with the adjusting nut off the end of the thread, push it through the hole separately first.

    Anyways ….. it all went back together in a couple hours as I knew where things went by then. So, although the clutch cable itself was easy to fit at each end, the job itself was far lengthier than the part alone due to access issues. So if you need to do it, it can be done but beware the lengthy extraneous work. And of course be careful with airbags, you must treat them with respect and follow correct procedures to avoid them being triggered which would be a real nasty surprise.

    BTW the clutch is super light now, problem solved. Enjoyed that first drive, it felt like a new car.

    clutch_cable_end.JPG dash_on_floor.JPG no_dash.JPG
     
    Last edited: Apr 13, 2016
    buz graham likes this.
  4. Sulley

    Sulley Copenworld Newbie

    Joined:
    Jul 10, 2011
    Location:
    Sydney, Australia
    Car(s):
    2004 Copen
    Great report ... my clutch has gone very heavy recently. I'm at 130k km and I think it's the cable needs adjusting. If I put it in 5th gear and handbrake it ... it still stalls ... so that's good enough for me to have a go at adjusting rather than replacing.

    Where? How? is the access to the adjustable end of the cable? Is it in the footwell or the clutch end? Sorry ... I haven't been under there in about 8 years and can't remember.

    Pics would be great if you have them so I know what I'm looking at.

    Cheers
    Andre
     
  5. Number6

    Number6 Copenworld Veteran

    Joined:
    Apr 25, 2013
    Location:
    Dublin
    Car(s):
    2005 0.7L Copen
    From memory, the adjustable end of the cable is just above the clutch pedal / part of the clutch pedal assembly.

    This is in contrast to the throttle cable, which is adjusted as part of the intake
     
  6. tictac

    tictac Copenworld Member

    Joined:
    Oct 8, 2013
    Location:
    Melbourne, Australia
    Car(s):
    Copen 2004
    Prius 2006
    The adjustment for the clutch cable is at the engine end, not at the cabin pedal end. You can get to it quite easily from above, just follow the clutch cable from the firewall to where it attaches to the engine clutch lever. There is a round plastic adjuster 'nut' on the threaded end of the cable in the engine bay where it attaches to a fixed mount, see my photo in the post above of that end of the cable (note that in the photo I have bent the cable 90 degrees sideways to show how I manoeuvred it through the firewall when removing/replacing the cable). Just take some pressure off the cable by pushing the clutch lever a little at the engine end then adjust the threaded plastic nut, it will rotate and self-position with a detent every 1/4 turn or so. Maybe you need a little WD40 on the thread beforehand if it is hard to turn. Correct free travel adjustment is 10 to 30 mm (upper surface of pedal pad), you must have some free travel so that the clutch is not held engaged slightly by an overly-tight cable.

    Having said the above, if after cable adjustment the clutch is 'stiff' or 'heavy' then cable adjustment alone is unlikely to help. This was the issue with my car, the underlying issue was a worn / slightly corroded inner cable which did not slide easily therefore needed to be replaced. If free travel is fine and the clutch engages fully, and you then have clutch slippage, then it is likely a clutch issue. If the clutch does not slip but it is 'stiff' to use then I would suspect you need a new cable like my car did, replacing the cable made a heck of a difference.
     
    Your Majesty likes this.
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