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Clutch Cable replacement. What a pig of a job!

Discussion in 'Introductions' started by Stealth, Aug 3, 2019.

  1. Stealth

    Stealth Copenworld Newbie

    Aug 2, 2019
    Hello Guys

    My girlfriend puchased an 07 1.3 Copen back in April I think and we noticed then, the clutch was very heavy. After a bit of research here it seemed that it was most likely the cable. It was getting to the point that gear selection was becoming in possible.

    I knew that it wasn't going to be easy, based on a few threads here, but couldn't understand why, until yesterday at least when I did the job. What a stupid design!

    Anyway 9.5 hours later car was back together and drives like new now. But what should of been an easy 60 minute job was exceedingly difficult because of the poor deisgn of the bulkhead hole behind the heater matrix. Big thumbs down for that.

    I've attached a few pictures of the nightmare I faced lol

    I'll try and get my girlfriend to join up as shes really eager to come to some meets and bring the car along. When is the next one? We're in Nottingham so anywhere in the East Mids would be great! Shout out to the few cars we've seen driving around the area.

    IMG_20190803_091736.jpg IMG-20190802-WA0006.jpeg IMG-20190802-WA0012.jpeg
    AFR0N1 likes this.
  2. AFR0N1

    AFR0N1 Copenworld Regular

    Mar 22, 2018
    Daihatsu Copen L880K (KMVZW)
    Oh wow, that looks like it was a pain to do. Well now its all sorted you can drive knowing you wont have to do it ever again for many years to come.
  3. Cathy in Liverpool

    Cathy in Liverpool Copenworld Newbie

    Jul 31, 2019
    Copen 1.3
    Can I ask where you got the clutch cable from? Is it right hand drive? Only left hand drive cable is available.
    I have explored every avenue over the past 3 weeks. My car is still sitting in the garage.
  4. PaulGee

    PaulGee Copenworld Member

    Apr 11, 2015
    Daihatsu Copen 1.3
    Daihatsu Materia 1.5
    Honda CRV (MkII)
    Out of interest how does the clutch feel now? I've always felt the clutch was heavy in our 1.3 but figured that might just be the seating position....
  5. Edweldo

    Edweldo Copenworld Newbie

    Jun 19, 2017
    Perth Australia
    2004 Daihatsu Copen
    Hi Cathy in Liverpool. I am guessing you have a right hand drive Copen? I replaced my right hand drive Copen clutch cable but also had to re-build the very weak mount as you can see by my previous communications. If you have the dash out it is worth checking out the mounting because its a devil of a job to fix later on if its cracked. Anyway i got my cable from Toyota, they took over Daihatsu.

    Paul, the cable should prob need replacing at around 130,000km and is typically smooth when replaced. If its stiff you are causing fatigue to the mounting bracket and mine developed significant cracks before the cable actually snapped. Previous owner did a 'repair' but still wasn't the best. Mind you my copen isnt the same as yours so they may have engineered a better mount.
    PaulGee likes this.

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