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yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: rlp11 ()
Date: October 11, 2019 10:51AM

Clutch Cable Failure Reason 1. And a shameless plug for my cable pulleys.

I may have found a reason that we are having so many clutch cable failures. It is the pulley design.

Pulleys are designed so the grove is the same diameter and the cable. 1/8 inch cable should use a pulley that has a 1/8 inch grove. Closer to a perfect fit the longer the cable life.

Picture one shows an OEM plastic pulley ,on the left, and a Repo plastic pulley on the right. See the difference? Repo pulley is flat on the bottom and the OEM is less flat. Grove is still too wide for 1/8 inch cable.

Picture two shows what the cable looks like in the plastic pulley. Real sloppy fit. This will let the cable flatten out when pressure is applied to the cable over the pulley. Using a 1500 pound pressure plate there is over 340 pound of pressure on the cable. This flatting causes early failures due to excess ware fatigue.

Picture three show the cable in one of my designed pulleys. I machine the grove to be the same size as the cable. Very hard to get a good picture due to all the shiny metal.

Comments welcome.

Roger Parent
El Cajon, CA
1964 Monza Driver
1964 Monza Project

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: Mel ()
Date: October 11, 2019 11:10AM

Chinese never can seem to make repro crap correctly sad smiley

Orangeville, Ontario. CANADA

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: larry202br ()
Date: October 11, 2019 11:27AM

It's interesting that you can actually see what appears to be a wear mark in the groove of that aftermarket pulley.

1961 rampside with a 65 / 67 110 engine, car four speed.
1965 convertible
1966 Custom two door/four door 180 Turbo.

KC0SKX
Olathe, ks
HACOA

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: rlp11 ()
Date: October 11, 2019 11:29AM

Both OEM and the after market pulley are new, never been installed. Black mark is manufacturing error.

Roger Parent
El Cajon, CA
1964 Monza Driver
1964 Monza Project

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: davemotohead ()
Date: October 11, 2019 11:52AM

So a combination of the bad repop pulley and the bad (Less strand) cable = early cable failure. Funny, I have always run NOS pulleys and cables and have never had one break! Good detective work Roger!







1960 4dr sedan caveman car
1961 Rampside (Chetside)
1962 Rampside (Barnside)
1962 Short Rampside (Shortside)
1962 Monza 700 Wagon
1963 Monza 900 coup (General Nader)

-----------------------------------
Rust Free Lancaster Ca

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: rlp11 ()
Date: October 11, 2019 01:23PM

Dave

I have always run NOS pulleys and cables till I started to make the pulleys and cables. Never broke a cable in 25 years.

Roger Parent
El Cajon, CA
1964 Monza Driver
1964 Monza Project

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: MonzaDave ()
Date: October 11, 2019 03:28PM

Roger, what is availability and price on your cables and pulleys?

Dave Keillor
Rochester, MN

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: 48kb1panel ()
Date: October 11, 2019 07:55PM

I'd like to know about availability also

My name is Mike Worrell living in southern Iowa my vairs are a 64 2dr convertible monza 900 with 110 motor 4 speed light yellow with blk interior. Then a few months ago I got a 65 2 Dr convertible monza 900 with 110 motor 4 speed
Also light yellow with blk interior. Not sure what gear ratio as of now I'll have a look and up date. I really like them both but really liking the 65. They really made a lot of changes in a 1 year difference ????

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: 66vairman ()
Date: October 11, 2019 08:01PM

Roger - Two questions.

1. Does the aluminum pulley Clark's sells have the proper groove shape?

2. If you offer a cable warranty does it require using your pulley?

Regards.

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: rlp11 ()
Date: October 11, 2019 11:13PM

Monzadave:

Pulleys will be available after Nov 1st. I am stocking up for the TOSS in two weeks.
60-64 Clutch pulleys are $25 each or $70 for a set of three. The 65-69 clutch pulley is $19.50.

66vairman:

Just went out an compaired them. The Alum pulley that Clark's sells has the same shaped grove as the OEM plastic ones.

Roger Parent
El Cajon, CA
1964 Monza Driver
1964 Monza Project

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: F125AXer ()
Date: October 12, 2019 06:28PM

The only cable failure I recall from many years back is one that broke right at the front end, where the ball was.

I attributed it to a lack of pivoting in the fork of the clutch pedal lever. I noted that the arm swings in a shallow arc, effectively bending the cable at the ball every time the clutch pedal was used. Polished the ball, and the pocket it rode in, and greased both. No further problems.

Perhaps new cables have a better attachment system. It is on the list of improvements I'd like to make when I can finally retrieve and drive my car again.



Note: This information is based on ancient history. My Corsa has been in storage for over two decades. But I am getting so dang old that if I don't retrieve it and make it run again soon, it'll never happen. Reading the phorum is motivation for me.

Alan Sheidler
Michigan
'66 Corsa 140 (mothballed)

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: American Mel ()
Date: October 12, 2019 07:27PM

As Alan stated, the only cable failure I have experienced so far, has been at the very end, not near the pulleys.
I made a "Temporary Fix" to get me home, and it is still in place approx. 7(?) years later. grinning smiley

-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
WA. state, 1 mile south of the Canadian border,
I am not at the end of the world, but you can see it from here.
Have; '66 Monza Coupe - 140, 4-spd. Daily driver beater
'67 Monza Vert. - 140, 4-spd. Daily driver beater
'67 A/C Moredoor Monza - Sale pending
Have had; '61 Monza coupe, '62 Monza Wagon, '63 Spyder, '65 Corsa
.
non-vair
'04 Dodge Cummins Quad Dualy, approaching 400K
17'Terry

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: MattNall ()
Date: October 12, 2019 07:35PM

That's an OEM cable....

How soon some forget...

Replica cables have been failing the cable... under the floor.... most times barely a year for a daily driven car..

MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: momach ()
Date: October 12, 2019 07:48PM

The new design pulley is aluminum? And the stranded cable is stainless? Do these ever get wet?
If so, there could be some concern for electrode potential from dissimilar metals.

Wet side of Washington State

one too many cars,(maybe)

multiple Corvairs.
1962 Buick Skylark
1967 Datsun 2000 roadster

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: joelsplace ()
Date: October 12, 2019 07:51PM

Only if you drive your Corvair in a lake. I guess the bottom EM pulley might get wet when driving down the creek like the GM ad shows. Maybe that is why the pulleys are plastic.

Joel
Northlake, TX
5 Ultravans, Lost count at 100 Corvairs...

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: caroseiii ()
Date: October 12, 2019 08:06PM

The problem I have seen the most is that the steel bushing rusts to the bolt on the lower pulley. The pulley itself then fails to pivot and the cable just rubs it away as the cable is actuated.

Crawford Rose

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: American Mel ()
Date: October 12, 2019 08:08PM

caroseiii Wrote:
-------------------------------------------------------
> The problem I have seen the most is that the steel bushing rusts to the bolt on the lower pulley. The pulley itself then fails to pivot and the cable just rubs it away as the cable is actuated.
>
> Crawford Rose

Just did a drivetrain conversion this summer, and I could have sworn that the bushing was aluminum.

-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
WA. state, 1 mile south of the Canadian border,
I am not at the end of the world, but you can see it from here.
Have; '66 Monza Coupe - 140, 4-spd. Daily driver beater
'67 Monza Vert. - 140, 4-spd. Daily driver beater
'67 A/C Moredoor Monza - Sale pending
Have had; '61 Monza coupe, '62 Monza Wagon, '63 Spyder, '65 Corsa
.
non-vair
'04 Dodge Cummins Quad Dualy, approaching 400K
17'Terry

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: caroseiii ()
Date: October 13, 2019 07:19PM

Ha-ha! An aluminum bushing? Yours was just super nice. The bolts will rust/corrode into aluminum as well. This is why the aluminum pulleys are an improvement in strength but may have dissimilar metal issues if the bolt is not lubed. the original 1960 steel brake cable pulleys used a nylon bushing between the pulley and the bolt. I don't recall the clutch cable using a metal pulley in the 1960s I had.

Crawford

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: Cheepfk ()
Date: October 14, 2019 05:28PM

I don't get it.
Both my 49,000 mile 1962 4-speed and my 88,000 mile 1965 Corsa have the original 55+ year old cables and pulleys and I have no problems.
Like Motohead states NOS replacements work well too.
I have two back-up NOS cables for each of my cars should I ever need them but so far so good.
It seems to me the problem with breaking cables may lie elsewhere especially considering so many Corvairs are poorly maintained and serviced on a low budget.

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Re: yawning smiley One reason for early clutch cable failure yawning smiley
Posted by: MattNall ()
Date: October 14, 2019 06:14PM

Many cars today have 300k 400 k on them...

And once again... not the NOS cables.... it's the replacements...they have too few strands....

MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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