BP G5M-R clutch cabling! A new alternate solution!

[Afro]

Doing a BP swap with a G5M-R transmission, I wanted a simple system for the clutch cable. Preferably no hydraulic installs, no door hinges, or pivots to clutch masters to slaves. I ended up taking a long time to find the solution but I think it was worth it. I hope it proves to last well because it's infinitely adjustable and an easy fix if anything goes awry!

--The Install--

So the first thing I did was find a beefy throttle cable at the wreckers that was longer than the Festiva clutch cable. I thought I could make it work, so I built a bracket, tested it but found that the cable stretched too much and slipped out of its retainers. Turns out throttle cables are not nearly tough enough for the job. Not surprised, but I wanted to try.

Plan B: Look for a longer clutch cable in all the cars at the wreckers. The cable must be similar to the Festiva's at either end and have just the right amount of action, adjustability and minimal distance between bracket point and end-of-rope point (I just made those terms up...)

So the clutch cable comes from an '84 Volvo 240, obviously with a manual transmission. The wonderful thing about this cable is that it uses a metal flexible sleave, much like those on some old desk lamps. This makes it stronger and less prone to deflection when stressed. Additionally the cable-tension adjuster works by winding itself up and down this flex-sleave! This means you could technically adjust it along the ENTIRE length of the ENTIRE clutch cable. Love it.

So I first found a point on the transmission to mount the bracket that would provide a little bit of aluminum meat to support the torsion from the bracket when your pushing in your clutch. This spot was ok:


But it meant that I had to do some extra work on the braket mounting point to clear that tab (yeah I could have cut off the tab, but I don't like to). Here's what the bracket looks like:


The cable itself has a nice big ball on the transmission end, so you just cut a little slit into the clutch lever and slide it in and the ball will naturally recess itself in the pre-existing divot:


Here's the same shot pulled back a little:


The interior end of the cable resembles the Festiva one, except that it has a removable pin. It's easy to install and sits like the stock one. The plastic retaining tab on the cable also fits nicely into the bracket on the clutch pedal frame (ignore the crazy greasy dust, it hasn't been cleaned yet!):


Here's a closeup of the end:


This is a closeup of the adjustment ring on the cable. The ring rotates and slides itself up and down the ridges on the cable sleave - ingenious and simple:


All installed and cinched up! A couple tests proved it to work fantastically:


I'll let everyone knows how it goes after the rest of the car goes together and its had a couple slow rush-hour drives.

[David88]

That is some awesome ingenuity there. I wonder what span of years those240s had that cable? Can anyone here that know Volvos enlighten? This definitely looks like a good solution so far! Thanks for sharing.

[Afro]

I checked out many more volvos at the wreckers and found that the later years all use hydraulic (740s etc., I think from 86 or so onwards). I'm no volvo expert though and the only other one there that was in the same range was an '82 and it was automatic

I also looked at the cables from a few other cars. I found nothing in Chrysler that would fit easily. Looked at late '80s Subaru Loyales but they looked a little short and not as good of a fit. Same deal with the 80s VWs. Found some automatic shift cables in the Toyotas and Nissans that might work, but it would be clumsy and they would be extra long. Looked at all other Fords and imports and found nothing really. If anyone finds anything else let me know, but BY FAR this has been the most amazing clutch cable I've found.

[Afro]

Oh! And the Volvo cable doesn't come with a boot (the plastic retainer that I used on the interior was actually used as a seal on the firewall in the Volvo). Just cut a slit down the Festiva one and slide it on the Volvo one then silicone the cut you made back together if you care to do so.

[bhazard]

If rock auto has them they'll show what years the part number works in.

[Afro]

They don't appear to have it.

[Rocketman]

I had to replace a clutch cable on a friend's 88 or 89 honda accord carby, it was a real long cable with very similar fittings to your volvo cable. Might be worth looking into.

One suggestion - gusset your cable bracket where the adjuster sits. The 90° plate supported only by the weld will be prone to cracking, it's under a lot of stress. Looks great though, very nice work!

[htchbck]

The one on my '89 Accord LXi was very similar to that as well. Hondas are probably a good option for longer cables because the trans is on the "wrong" side lol. I will get a volvo cable and do this for Keith's car probably, I like the idea of keeping it cable instead of trying to mount an MC

[Afro]

I'll take a look at some Hondas tomorrow when I go back to the wreckers because I need a couple more cables and there's no more Volvos. The Volvo one is the perfect length though, so anything longer would be a little less than ideal.

One suggestion - gusset your cable bracket where the adjuster sits. The 90° plate supported only by the weld will be prone to cracking, it's under a lot of stress. Looks great though, very nice work!

Also, no need to gusset Rocketman. The 3/16 steel bar that forms most of the bracket is bent underneath the steel 1/8 plate (with the hole in it) right up to the hole. I'll post a picture tomorrow of it, but you can kind of see the discolouration in the 1/8 plate from the welding. It's rock solid and shows no flex at all.

[Bert]

Nicely thought out, well done, and clean looking! Congratulations.

[Afro]

Took a look at some old Hondas today, looks promising too although the one I saw has a 2 inconveniences:
1. REALLY long, you guys weren't kidding. You might have to do some loopty loops with it.
2. The transmission end isn't a ball, but rather a kind of flat plate meaning it won't fit as seamlessly into the clutch lever.

The adjuster is real nice though and similar to the Volvo one. Couldn't get a look at where it clips into the pedal, because there was a bunch of stuff in the way and I was stressed for time. But if no Volvos are around, I'll have to go back and make it do.

[Christ]

Took a look at some old Hondas today, looks promising too although the one I saw has a 2 inconveniences:
1. REALLY long, you guys weren't kidding. You might have to do some loopty loops with it.
2. The transmission end isn't a ball, but rather a kind of flat plate meaning it won't fit as seamlessly into the clutch lever.

The adjuster is real nice though and similar to the Volvo one. Couldn't get a look at where it clips into the pedal, because there was a bunch of stuff in the way and I was stressed for time. But if no Volvos are around, I'll have to go back and make it do.

Most Honda/Acura cables use a flat lug with a plastic washer behind it that may or may not lock into the pedal hole and does act as a bushing for the cable movement and to stop the cable from "slipping" back through the slot you feed it into.

The lug type is called a "TEE", it looks like a boat anchor of sorts (the mushroom kind).

[htchbck]

Found the '82 one at NAPA, they want almost $50 for it though, gotta call once the store opens and see what I can get it for though, if its $30 or less I may pick one up. Just so you know, apparently the Italian built cars had a different cable (according to NAPA's website) than the German ones. German one is the one that Afro posted with the spiral metal sheathing that is awesome. The Italian one could probably be made to work as well, but its not infinitely adjustable. NAPA lists it cheaper, but also doesn't show any at any of their warehouses. For refernce:

German:



Italian:

[Rocketman]

Most Honda/Acura cables use a flat lug with a plastic washer behind it that may or may not lock into the pedal hole and does act as a bushing for the cable movement and to stop the cable from "slipping" back through the slot you feed it into.

The lug type is called a "TEE", it looks like a boat anchor of sorts (the mushroom kind).

The Honda one I replaced had the link type that slides into the notch at the top of the pedal. Rockauto has a couple pics. (for 88 accord, $28 from Dorman)

[mr2gq]

I looked the car up there's no volvoe 240 listed. However there is a 242 244 ect. But I found the cable you have and it fits volvoe makes an years, 242-1975-84/ 244-1976-88/ 245-1975-88. Oreillyautoparts.com tells you the compatibility of all parts. It's great.