Clutch Tube Repair.. WITH PHOTOS

Bugaru "JAY" · August 23, 2008, 09:11:52 PM

Ok. Never did I expect to hit this problem but I beleive that someone "hint like Mr GT-1 himself" put the Broken Clutch Tube Blues on me. Can't be 100% sure but I do beleive that I parked a little to close to his ill car once to many times. I know that Bob just fixed his clutch tube but not sure if he started a topic on it. Little did I know that when I sent Bob info on where to cut into the tunnel etc, that I would be doing the same job on my own car shortly afterwards. So I'll try to document the work so others can see what there have to face when it occurs. Unfortunatly I don't have dawelder dude and Jack won't share, so I'll have to do it myself and try to take pics at the same time? Do you think that supper glue or that there JB Weld appoxy thing-a-ma-gig will hold it?

I just installed a new trans, and improved engine, and also clutch assembly but after putting my clutch cable onto my new trans throw out lever I noticed that the clutch cable just didn't seem taught enought. After further research I noticed that sure enough the clutch tube had some movement in it. After further research I found that all three of my welds are broken loose. Now how the F could that have happen, when all worked well before I disasembeld the engine and trans. Oh-oooo well I guess that the stageII clutch assembly took it's toll. :wallbash:

Sundays project will be to unbolt and remove the passengers and rear seat, and carpeting and do some cutting into the Tunnel to reweld the front, center, and rear clutch tube mounting locations. While I'm in there I'm also going to replace the clutch cable with a fresh new one. Also while the brake/clutch pedals are removed, I'm going to upgrade my brake master cyl to a New Style DisC Brake unit that I just picked up. It has a 20.5 mm piston in it for better Disc Brakes stopping power. Like I mentioned above I'll try to remember to take some pics. s#r But still stumped how this could have happend when I had a great clutch pedal before the trans swap? stoned#

njgt-1 · August 24, 2008, 06:33:06 AM

Jay,

I don't think its contagious and my Bradley was never close enough for the "Clutch bacteria" to get your car!

I did the job a couple of weeks ago with Mikes help. I didn't document it or even take any photos because we did it in one long thrash. I wasn't sure just what or how I would fix it but we opted for the "no weld" method since my tube had broken only in the center. I made up a bracket just like the guy on the Samba thread, chopped a hole in the tunnel, bolted the bracket in position and vola! the clutch was back! This wasn't an easy job but with the clutch tube finally stabilized and the carpets back you would never know I had this problem.

The Samba article can be found here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=120362&highlight=clutch+tube+repair

The repair with the fabed out bracket is here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=236748&highlight=clutch+tube+repair

I don't think the bracket method will help you out since your tube is broken in 3 places but the idea is similar. Good luck! and if you can post some photos.

lovebus (jack) · August 24, 2008, 02:29:00 PM

Jay, weld it or down the road it will start to move on you again.

Bugaru "JAY" · August 24, 2008, 10:04:37 PM

OK Guys. Here are a series of pictures to show you what your have to deal with if you wish to solve a broken Clutch Tube weld, Front, Center, or Rear. Mine just so happened to be broken at all three locations, Front, Center, and Rear. Lucky me, and lucky for you guys I took pics.

Catuion. If your going to attempt to weld any of these locations, please use caution, as the fuel line is just above and the throttle cable runs right along side and is attached to the clutch tube. So if your welding and burn through something your either going to fuse something together or might as well kiss your mooning goodbye. Poof

I used the standard measurment as found on a few VDub repair sites. But apperently the early cars like mine has the center tube mount at a different location. See Pics.

This is the New Improved Center Support that I made. It will now support the Clutch Tube from two locations, instead of just one like the orginal bracket that always breaks lose, thus your need to do this type repair. The New Bracket is over twice as thick as the orginal, plus now will have two points of support, unlike the orginal tin bracket that simply hung there and vibrated loose etc over the years and it only had one mounting point.

I'm running a Beefy StageII Clutch and Presure Plate Setup, and wanted to be sure that this never happened again. This new improved Center Support will last longer then the car?

Front Of Clutch Cable with Brake Pedal assembly removed. Note Wear on the loop, this is where it will catch onto your clutch pedal assembly. Replace the cable even if it dosn't show wear, hell it's only a $6.00 item. Don't forget to lube the chit out of it!!

The Freaken-Fracken Front of the Clutch Tube also had a Broken Weld!

Working or welding inside of a VDub Tunnel is not as easy as it looks. It's thight in there, and before you cut becareful because there is much more stuff in there then one might think. Things like Heater cables, Throtle cable, Clutch Cable, Shift Rod, Fuel line, etc.
Good Luck 2 You. Jay s#r

njgt-1 · August 24, 2008, 11:24:57 PM

Jay,

Great job, looks like you got the "triple headache".
I can see welding was the only way out of this one but looks like it now
will outlast the car! glad you remembered the photos.

6T5 square · August 25, 2008, 07:42:23 AM

I'll bet the toughest part is keeping that carpet clean :icon_wink:

Baha (Shawn) · August 25, 2008, 08:36:45 AM

The most important question is what motor are you running that you have an EM computer? aliencomputer
'Cause if it's a carburated bettle motor I've got a million questions

njgt-1 · August 25, 2008, 10:00:43 AM

QuoteThe most important question is what motor are you running that you have an EM computer?
'Cause if it's a carburated bettle motor I've got a million questions

Hey you are going to have a couple of million more, Jay runs subie ( suburu ) motors in his cars! you have to see them to believe it can be done!

Bugaru "JAY" · August 25, 2008, 10:28:41 AM

This car has a fresh Subaru 2.5 non-turbo engine in it. Estimated 200 HP. I'll be starting a new thread on this build shortly, but here are some pics.

Enjoy Jay shocked

Baha (Shawn) · August 25, 2008, 01:19:33 PM

#@$ #@$ #@$ #@$ #@$ wow*

VWPANZER1 · August 25, 2008, 01:59:40 PM

Jay:

Great job on the repairs and even better job on the photo's and explainations. weldface

You do good work!

JT

njgt-1 · August 25, 2008, 02:31:09 PM

Looks like it was made to fit in there!
200 reliable HP what a concept!

lovebus (jack) · August 25, 2008, 03:49:33 PM

BO** BO** Yhaaa, Jay posted photos :icon_thumright:

Very good job on the tube repair Bug-A-Sue!! U da Man.

Bugaru "JAY" · August 25, 2008, 04:11:22 PM

Quote from: LoveBus (jack) on August 25, 2008, 03:49:33 PM
BO** BO** Yhaaa, Jay posted photos :icon_thumright:

Very good job on the tube repair Bug-A-Sue!! U da Man.

If I'm Da-Man why you calling me Sue. I've got a dog named Sue she's a good girl. Well sometimes but only when she barks when I tell her too, whoops gots to get her diner together before she gets home from work.
s#r