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Thread: Help with modifying a clutch cable

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    Default Help with modifying a clutch cable



    I am looking for a high quality replacement clutch cable for the cj....The common Crown versions are notoriously bad for breaking after a few years - I just broke my 2nd one in 7 years. A company called Inline Tube makes highly recommended, made in the USA cables - but the one they make for my CJ isn't quite the right dimensions:
    https://www.inlinetube.com/products/sftj01

    The housing length is fine, the inner cable is about 3-3.5 inches too long....when I chatted with them on the phone, they didn't seem to want to make me a 'custom' one. Would anyone on here be able to cut the cable (they make both stainless steel and standard steel cable options) end stop off and add a new one up 3 inches (I think its just a 'compression sleeve' fully crimped barrel type thingy). Or maybe HF or someone makes a cheap tool I can do this with?

    Or maybe just get the oem steel one and weld some sort of stop on the end?

    thanks
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    How different is the housing and cable from a bicycle brake cable? Would a brake cable and housing cutting tool help?

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    Default Re: Help with modifying a clutch cable




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    Default Re: Help with modifying a clutch cable



    open_circuit previously posted:
    "How different is the housing and cable from a bicycle brake cable? Would a brake cable and housing cutting tool help?"

    it's less about the cutting and more about putting the new compression sleeve stop barrel on the new end. This is way bigger than a bicycle cable.
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    Guess I was thinking more along the lines if one of our members worked in a shop that has the proper tool and swage wire stop to make the proper end stop. I can cut the wire, and housing is perfect as is, just need to remove 3" or so of wire and put in a new swage stop with a hydraulic press/crimper - just not sure who or what kind of place does that stuff.
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    Might try looking up a swaging tool, or how to swage cable to see if a relatively cheap tool and cable end could be something you would consider as a DIY for your purpose.

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    Default Re: Help with modifying a clutch cable



    Brian previously posted:
    "Might try looking up a swaging tool, or how to swage cable to see if a relatively cheap tool and cable end could be something you would consider as a DIY for your purpose.
    "

    Was wondering if this one from HF would do the trick....not sure if it could handle steel or stainless steel wire...?
    https://www.harborfreight.com/hydrau...SABEgJpGvD_BwE
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    If you can come up with the swage tool - a bunch of us has shop press's.

    Optionally, if you're looking to have a cable made, I had custom length parking brake cables made for the jeep. Here's the place that did it (California).

    https://www.controlcables.com/

    I would use them again. As I recall, their web site was lacking one detail so I called. The phone was answered where I could see their business being one to three guys with the phone in the shop. One call - done and exactly what I asked for was shipped in good time.

    Maybe they'd be able to help?

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    Default Re: Help with modifying a clutch cable



    FINOCJ previously posted:
    "Was wondering if this one from HF would do the trick....not sure if it could handle steel or stainless steel wire...?
    https://www.harborfreight.com/hydrau...SABEgJpGvD_BwE"


    I'm not sure if that would give you enough crimping power. When I was using them with some regularity they were a two handed tool with good leverage. More along the lines of a bolt cutter size.

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    Default Re: Help with modifying a clutch cable



    Brian previously posted:
    "I'm not sure if that would give you enough crimping power. When I was using them with some regularity they were a two handed tool with good leverage. More along the lines of a bolt cutter size."

    the manual ones are big like bolt cutters - the HF one i posted is hydraulic assisted
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    I have both of these, if you can find a fitting to crimp your more than welcome to try either one.




  12. The Following Member Says Thanks to newracer For This Post:

    FINOCJ (June 5th, 2020)

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    Default Re: Help with modifying a clutch cable



    Its can be complicated trying to get parts for old stuff...in short, I ordered the Inline Tube cable and we'll see what happens. If it works out of the box, great - if not, then I'll figure out how to modify it. There is new hope that it might work as is....The sales rep got me specific specs of the different parts (length of cable, length of housing, length of each end fitting), and if those numbers are what I actually receive, then it will work perfectly. On paper, its designed correctly. But what is concerning is a jeep acquaintance ordered the same part and got a cable that was 3 inches too long. All the other aspects are exactly the same and would be correct - its just a 56" cable instead of a 53" cable (he is contacting them to see what they have to say - maybe get it exchanged for a correct one). So, we'll see what I get: if its the 53 it'll be perfect, if its the 56, then we are calling the company to see what we can do and/or just modifying it to work. June 12 is the magic day....until then, I am working on the willys wiring and electrical fan project.
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    FINOCJ previously posted:
    "the manual ones are big like bolt cutters - the HF one i posted is hydraulic assisted"

    Opps! Sorry I missed that hydraulic assist part. That's pretty neat actually.

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    Default Re: Help with modifying a clutch cable



    I received the inline tube clutch cable and looks like ti comes just as they report - and that it should work just fine with no mods:
    I ordered SFT-J01 (SS) - the SS is the stainless steel version.
    OAL of the cable is 58 1/4"
    Length of just the cable is 53"
    Length of the cable housing (mating surfaces) is 39 5/8"



    I haven't installed it yet, but it does match up exactly with the Crown version - so it looks exactly right. Just as expected, the pedal clevis will need some bending/opened up a bit, but other it looks good and hopefully will solve this problem for a long time - now I just need to find one of the two 'clips' that secures the cable housing ends to the frame brackets (I know both of them were on my work bench just yesterday! )
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    Glad it looks to be correct. A few days earlier as I recall too? Bonus.

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    Default Re: Help with modifying a clutch cable



    Getaklu previously posted:
    "Glad it looks to be correct. A few days earlier as I recall too? Bonus."

    That means he can finish fixing the CJ early and has time to get the wagon ready for china wall!

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    Default Re: Help with modifying a clutch cable



    Today was dedicated as a jeep work day....and as of 1pm I've gotten very little done due to all sorts of other distractions that seem to need my attention....oh well, maybe this afternoon I can make progress....
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Help with modifying a clutch cable



    Inline tube replacement fit perfectly...hardest part was the square metal clips that hold the cable housing at the brackets were a bit mangled from use and re-use. Ended up making one from a 1/16" thick metal shim with a 3/8" notch....feels pretty darn solid, but I'll be checking it often to make sure its not going anywhere (and have a spare as well).


    Clutch pedal feels exactly the same as with the Crown version - hopefully it won't do this:
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

  20. The Following Member Says Thanks to FINOCJ For This Post:

    Tom (June 10th, 2020)

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    Default Re: Help with modifying a clutch cable



    FINOCJ previously posted:
    "Inline tube replacement fit perfectly"

    SWEET!!

    Congrats. Medano Pass this weekend?

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    Default Re: Help with modifying a clutch cable



    Jim previously posted:
    "SWEET!!

    Congrats. Medano Pass this weekend?"

    Ruby-Horsethief Canyon river float on the Colorado River from Loma to Westwater: 3 day/2night trip this coming weekend. We've done this trip a couple times before - its total flatwater float, but the canyon scenery is nice and the warm weather, good swimming and cold beer make for a nice time. And we a stretching the trip to 2 nights so we can take a bit of extra time to relax, and do the hike up Rattlesnake canyon to the arches, and just because its nice to be getting out right now. Following weekend is China Wall so will be out for that. Making progress on the Willys, but everytime I say that, it seems to go downhill. Been doing some tedious wiring up under the dash - just spent the better part of 2 hours upside down trying to replace the speedo cluster bulbs and get some wiring down so the AMP light will work etc, and go all the dash lights rewired onto the correct terminal on the headlight switch so they come on with the parking lights etc. Also removed some extra wiring that I assume a previous owner used for something auxiliary (cb, radio etc). Still have to get a junction block for the keyed power supply mounted - that will be the keyed source for the electric fan relay, and it will also provide power to the auxiliary tachometer and eventually to a volt gauge I will put in place of the ammeter. That is sort of phase 2, and might include a fuse box etc - but for now this will get it running enough hopefully.
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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