Register Login
Mr FIAT - Your #1 source for vintage car parts
Comment
 
Guide Tools
<!-- google_ad_section_start -->899 Clutch Cable Replacement Guide<!-- google_ad_section_end -->
899 Clutch Cable Replacement Guide
Published by Jamieboy
19-01-2006
Unrated

User Rated:Unrated

Show Printable Version  Email this Page 
899 Clutch Cable Replacement Guide

Just done mine yesterday. The Hayne's excerpt is ok as rough guide, but misses out some of the more subtle points so I have taken it upon myself to write one myself. So here's exactly how for the 899cc:
899 Clutch Cable Renewal
Tools required:
  • 13mm socket ¼” or ½” drive
  • 10 mm socket ¼” or ½” drive
  • Short extension bar ¼” or ½” drive
  • Ratchet – ¼” or ½” drive
  • ‘Medium’ Phillips screwdriver – ideally 1 ‘normal’ shaft length and one either really short - shorter than 3” OR really long – bigger than 9”
  • Long nose pliers – ideally angled ones
  • 2x10mm spanners – ideally one of which should be an ‘open-ender’
  • A torch or inspection lamp.
  • Wheel key or suitable breaker bar with 19mm (3/4” socket)
  • Jack and an axle stand
  • WD40 or similar
  • Wire brush (optional)
  • Paper towel/rag
Hardware Required
  • M5 Nuts (10mm across) – optional
  • Multi-purpose grease - recommended
  • 2mm Split pin – DO NOT use the old one
  • Clutch cable
Before we start:
  • If you are working in the roadside, make sure the passenger side is nearest the kerb.
  • When you park it up to do this, try to get the wheels to point to the extreme left.
  • Make sure you have some daylight hours to do this

Removal:
  1. Open the bonnet and undo the 13mm nut that holds the air box in (to the right as you look at it). No need to open the air box or remove the air filter!
  2. Gently pull the air box straight up, a forward and backward wriggle helps get it out of the rubber inserts it seats into. There are 2 pipes which are a push-on fit that have to be carefully removed. The 1st is a rubber pipe which comes from the front of the engine bay and attaches onto the lower-half of the air box. The 2nd is a corrugated warm-air feed from the exhaust manifold
  3. With the air box free, it will flex on the main air pipe (gently now) and lie on top of the engine, with a little wedging.
  4. With that out the way, look down through the air box supporting frame and you should be able to see the clutch cable come through the pivot arm and rubber ‘stop’ and be secured with an adjuster and locking nut.


    We will now move to inside the car and release the cable from the pedal mechanism.
  5. Move the passenger seat all the way back and wind the seat down onto the rear seat. Next, take one of your floor mats out to kneel down beside the car at the passenger footwell. Take a look under the passenger side of the dash, specifically under the little metal frame document ..er.. shelf and you’ll see a metal cover on the bulkhead. Use your torch if it’s too dark. Use a Phillips screwdriver to unscrew the 3 screws that hold this one. The two bottom ones can be removed with any length screwdriver, but the top one is a little more tricky to get. You can use a very short-length screwdriver on it, up the back of the shelf, a really long one to go through an open part of the shelf frame or a crank-shaped screwdriver to get at it from below.
  6. Put the 3 screws and washers (yes, dig out that 3rd one that rolled into the corner of the floorpan) and put them in the metal cover that you just took off, and put that onto the dash.
  7. You should now be able to see more of the elaborate pivot and lever system of the clutch. The bit you are looking for looking at you end-on, with a split pin (or possibly clevis pin) going through it.
  8. Using your long nose pliers fold the split pin straight again and pull it out by the eyelet end. The washer behind it may slide off – no probs, put it in a safe place. Also, the cable may pop backwards out of the quadrant it’s in – don’t worry if that happens either. If it doesn’t come out by itself, push it out of the quadrant using a suitable poking device(!), then turn the now-revealed-to-be-right-angled cable end so that it points towards the driver’s side. You may notice that the clutch pedal has fallen to the floor… ignore that for now. If your cable has broken it will already be there

    Now we move to the passenger side front wheel. If you closed the bonnet – open it again to get more light down where you’re working.
  9. Crack off the wheel bolts then jack the car up at that corner. Lower the car onto an axle stand – DO NOT work under the wheel arch with the car supported only by the jack. Remove the road wheel and put it to one side along with the bolts.
  10. Look at where the clutch cable leaves the pivot arm from where you seen it from above and follow it towards the bulkhead. It bolts onto it with 2, 10mm flanged nuts at a strange angle (try and remember this for re-fitting). You may need to clean these off with a wire brush and give them a good scoot with WD40 or similar. You DON’T want to snap these. If you look at your new cable, you will see that the farther away mounting point is actually a slot. I thought I could take off the nearer one and only need to slacken the other one off a little…. Guess again. After you take off both, keep them safe – they’re teeny! Give a little tug on the cable and break the dust/mud/rust seal which may have formed.
  11. Return to the bonnet and look for the two nuts on the threaded section of the cable. Give the thread a clean to help nut-removal. Grab the nut furthest away from (adjuster nut) you with an open-ended 10mm spanner and put the 2nd spanner on the nearest nut (lock nut), ensuring one spanner-per-nut. Move the nearer spanner to your left and either hold the back one still or do a scissor-action on it to separate the two nuts. Remove both nuts and grab the square section piece of metal before it falls under the car. I presume the rubber stop comes off too, but mine just stayed in place with the power of old age.
  12. Push the threaded part through the pivot arm and through the bracket on the bell housing and tuck it out of the wheel arch where you were sitting a moment ago.
  13. Go back to the wheel arch and carefully remove the cable from the front-end 1st (you may need to untangle the cable from the flexi-hose and side repeater wiring) before removing the cable from the bulkhead (most likely the hooked part of the cable WILL catch on the hole it goes through – show it who’s boss) and remove the cable from the car. Sorry looking thing isn’t it?!
Refitting:
  1. Grab a hold of the new cable and carefully feed it back up the way the old one came out – the object here is to get as little rubbish on the threaded end of the cable and down the outer sheath. Do the threaded end 1st so it is poking out where you can grab it from above.
  2. Return to the under-bonnet and find the end u just fed-up. Carefully guide the threaded section through the bell-housing bracket and pivot arm at all the way, then the concertina boot, all the way until the big rubber stop comes up against the bell-housing bracket. Be especially careful not to split the concertina boot section as this will allow all kinds of demonic ingress. Put on the square-section washer and then either refit the old ‘adjust’ and ‘locking’ nuts (after a clean) or, as I did, replace them with M5 new ones (10mm across).

    Important: only put the nuts on the very tip of the cable at this point – you’re going to need all the slack you can get to re-attach the other end!

    Side note – on the old cable I took off and also on the (OEM) replacement I got, what looks like the word “SNAP” is stamped onto the bulkhead side of the fixing plate. No wonder people complain about them breaking – that’s a blatant jinx!
  3. Go back to under the wheel arch and carefully guide the right-angled other end of the cable through the bulkhead before pushing the fixing plate back over the studs (I am SO glad FIAT made these studs and not threaded holes for bolts!).
  4. Take a bit of multi-purpose grease and put a thin smear on the studs before re-fitting the 10mm flanged nuts. DO NOT over tighten – those studs would be a nightmare to replace.
  5. Refit the road wheel and take the car off the axle stand so that it is back down on the ground.
  6. back beside the passenger footwell, you should see the new right-angled end of the cable smirking at you in the corner. With the help of an assistant, or a carefully selected object, prop up the clutch pedal as high as it will go.
  7. This next part was tricky for me – you need to guide the cable back through the quadrant from whence the old one came. With the quadrant fixed in place, either with nimble fingers, or nimbler long nose pliers, gently grab the cable end and pull/push it through until it is all the way back. Don’t give it a chance to jump back out - take a suitable object – I used a fat-handled screwdriver to keep the end as far though the quadrant as it can go.
  8. Now, the REALLY fiddly bit: you need to put the gold washer back over the bit that’s sticking through and then secure it with a NEW split pin. DO NOT use the old one – you are asking for trouble. I lay upside down under the dash to do this – a torch really helps as does the angled long-nose pliers. The split pin feeds in from the side nearest the driver. Once that bad boy is in place bend his little legs back round the pin.
  9. Remove your cable end prop and move your clutch pedal prop-up so that the pedal is sitting roughly where it should be (11cm from one source or just above the brake pedal height from another source) then refit the metal cover under the dash – use all 3 screws, don’t chuck that top one – it looks as though that cover would cause an annoying rattle if it were left out!
That’s essentially the cable fitted! Yay! Now:


Adjustment:
  1. Return to the engine bay and coat the threaded part lightly with multi-purpose grease. Try to avoud getting any on the cable gaiter just behind here. finger tighten the adjuster nut (back one as you look at it from the front of the car) till it is up against the square metal washer.
  2. Go to the driver seat and remove your makeshift pedal prop. MAKE SURE the car is in neutral and the hand brake fully on start the car. Depress the clutch pedal and tentatively try 1st gear. For me, it went in no probs, with a nice, low biting point of about 2cm from the floor. With the old one, it only bit about ¾ of the way up.
  3. This really is a personal preference thing. If you want to make the biting point higher, tighten the lock nut (back one) till the desired point is found. Once you have, finger tighten the lock nut (front one as you look at it from the front of the car).
  4. Tighten the lock nut onto the adjuster nut by placing an open-ended spanner on the adjuster nut to hold it still then tighten the lock nut onto it (turn towards the passenger side). Give a generous coating of grease to the threads for future adjustment
Lastly – refit the air box:
  1. Split the box as though you were changing the air filter element by unfastening the four catches.
  2. Tuck the top-half around the front of the engine. Carefully remove the filter element and put it somewhere clean and dry. You should be left with the lower airbox in your hand.
  3. Carefully lower it down onto the 1st few centimeters of long threaded stud that it came from. Dip it towards you at the front and refit the cold-air feed.
  4. Next, push it farther down the fixing stud feel whilst feeling underneath to make sure that the pegs on the bottom of the box are lining up with the grommets on its supporting frame before fully seating it back into its original position. Refit the corrugated warm air feed from the exhaust manifold. Replace the upper portion of the air box and secure it with the fastners.
  5. Put on the washer and 13mm nut that came from the stud back on and tighten it finger tight then give it a further little turn - it needn't be over-tight.
DONE

Some pics to follow!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Old 28-02-2006   #1
ben
The Boss
 
ben's Avatar
Join Date: Mar 2002
Location: Taipei
Posts: 13,328
Thanks: 390
Blog Entries: 186
Trader Rating: 0
ben has donated!
ben is an honorary friend of the forum :)
King Pong Champion, e+Casino Blackjack Paper Champion, President vs Invaders Champion, Funny Clown vs Balloons Champion, Table Tennis 2.5D Champion
Taiwan 
Re: 899 Clutch Cable Replacement Guide

Great guide Jamie, unfortunately there is a bug in the guide software that just nuked the other copy when merging them! So all replies got zapped, sorry !
__________________


my name is ben, i live in the east, i'm always working on the forum, i like pancakes.

MAKE MITTENS FAMOUS - https://www.instagram.com/heymittens/
ben is offline Reply With Quote Quote 
Old 17-06-2006   #2
Join Date: Mar 2005
Location: Caithness
Posts: 193
Thanks: 15
Trader Rating: 0
United Kingdom 
Re: 899 Clutch Cable Replacement Guide

Quote Originally Posted by ben
Great guide Jamie, unfortunately there is a bug in the guide software that just nuked the other copy when merging them! So all replies got zapped, sorry !
Ah, no worries - I'm more interested in people getting the use out of it!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Jamieboy is offline Reply With Quote Quote 
Old 05-12-2006   #3
Join Date: Dec 2006
Location: North Yorkshire
Posts: 6
Thanks: 0
Trader Rating: 0
United Kingdom 
Thumbs up Re: 899 Clutch Cable Replacement Guide

Just read the guide, Thanks it will be a great help to the guy I sold my cinq to last night!! Cheers! Rowe33
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Rowe33 is offline Reply With Quote Quote 
Old 14-12-2006   #4
Join Date: Jun 2006
Posts: 29
Thanks: 0
Trader Rating: 0
United Kingdom 
Question Re: 899 Clutch Cable Replacement Guide

Hi, will this help me refit clutch cable in 1.1 sporting??
Thanx

Keith
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

peanut222 is offline Reply With Quote Quote 
Old 01-02-2007   #5
Get a wriggle on!
 
levemircento's Avatar
Join Date: Dec 2006
Posts: 1,760
Thanks: 89
Trader Rating: 0
levemircento has donated!
United Kingdom 
Re: 899 Clutch Cable Replacement Guide

attached pic may be of use
Attached Thumbnails
Click image for larger version

Name:	clutch.jpg
Views:	2196
Size:	26.2 KB
ID:	23626  
Thanks ellobo thanked for this post
__________________
must be time for a brew
levemircento is offline Reply With Quote Quote 
Old 06-06-2007   #6
Join Date: Jun 2007
Location: Bromley, Kent
Posts: 1
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: 899 Clutch Cable Replacement Guide

You are a God. Clutch cable all done thanks to you, although I had already removed the entire dash before I found this post (silly me). Thanks again.
Vince
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

vincentlloyd is offline Reply With Quote Quote 
Old 12-08-2007   #7
Join Date: Aug 2007
Posts: 1
Thanks: 0
Trader Rating: 0
Re: 899 Clutch Cable Replacement Guide

Wow,

Thank a million for this post, it was incredibly helpful.

One point for the Seicento, I only needed the screwdriver and the 10 mill spanner to do the whole job ( bar the Jack and taking off the wheel )

And for the replacement of the small clip ( split pin ) i used a paper clip, it was much less fiddly,but I do not know how safe it will be, but will reply to my own post if there are any disasters!

Once again, thanks for saving my already depleted pockets and boosting my ego drastically!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

tgems is offline Reply With Quote Quote 
Old 20-12-2007   #8
Join Date: Aug 2006
Location: Stratford-upon-Avon/Herts
Posts: 543
Thanks: 5
Trader Rating: 0
United Kingdom 
Re: 899 Clutch Cable Replacement Guide

very helpful thread, i didnt have a clue where to start untill i read this! so thanks very much

i took some pics along my way as i was working, to help illustrate the thread
(my car is 899 sei)

Airbox removal

Click image for larger version

Name:	DCFC0001-1.jpg
Views:	621
Size:	139.0 KB
ID:	35889


clutch cable beneath airbox mount

Click image for larger version

Name:	DCFC0002.jpg
Views:	558
Size:	111.6 KB
ID:	35890

Click image for larger version

Name:	DCFC0003.jpg
Views:	452
Size:	130.8 KB
ID:	35891

Click image for larger version

Name:	DCFC0004.jpg
Views:	438
Size:	136.5 KB
ID:	35892

into the bulkhead from engine bay...

Click image for larger version

Name:	DCFC0009-1.jpg
Views:	500
Size:	106.1 KB
ID:	35893


old and new cables... obvious which is which

Click image for larger version

Name:	DCFC0010.jpg
Views:	614
Size:	105.5 KB
ID:	35894
Thanks Jamieboy, custard thanked for this post
__________________
Dr Hillmann
Seicento SX - Breaking for spares
All in classifieds
http://www.fiatforum.com/classifieds...=10814&cat=500

Last edited by custard; 26-12-2007 at 05:28.
dr_hillmann is offline Reply With Quote Quote 
Old 14-02-2008   #9
Join Date: Jan 2008
Location: Stevenage, Herts
Posts: 3
Thanks: 0
Trader Rating: 0
United Kingdom 
Thumbs up Re: 899 Clutch Cable Replacement Guide

Great guide. easier than that haynes manual! I have purchased a modified clutch cable for my cinquecento as apparently the original tend to break easy on the 'L' bend near the linkrod pivot. just as mine did. pain in the ass! the modified on has a straight end with a bolt on it.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

rikkyjoy is offline Reply With Quote Quote 
Old 22-04-2008   #10
Join Date: Apr 2008
Location: Thurrock, Essex
Posts: 3
Thanks: 0
Trader Rating: 0
Ireland 
Re: 899 Clutch Cable Replacement Guide

Hi Jamieboy,

Just to let you know I have down-loaded your instructions on how to change a broken clutch cable on a Seicento. I am a [very old] retired mechanic. Last useful fixing I did was in the 80's. With your invaluable help I have shown my grandsons how to do for themselves. I hope you've got lotsa good vibes for the good work you did that day, sharing your knowledge with others. It costs nothing but it does need a giving nature to take the trouble.

You will be lucky 'cause all the good we do in life comes back to bless us.
So! Bless you!

Shaun
SouthOckendon
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

southockendon is offline Reply With Quote Quote 
Old 22-04-2008   #11
Join Date: Apr 2008
Location: Thurrock, Essex
Posts: 3
Thanks: 0
Trader Rating: 0
Ireland 
Re: 899 Clutch Cable Replacement Guide

Hi DR Hillmann,
I've said thanks to Jamieboy for helping a very old and very tired mechanic get up and go with his help. Now I want to say thanks to you for adding to Jamieboy's instructions with your pictures. A picture can be as good as 1000 words and you made things ever so easy for me. As I said to Jamieboy, it takes a giving and caring nature to help your fellow man. You may not make the front pages for what you do, but a lot of people get quietly helped as you pass gently through their lives.
Bless you!
Shaun.
SouthOckendon.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

southockendon is offline Reply With Quote Quote 
Old 22-04-2008   #12
Join Date: Apr 2008
Location: Thurrock, Essex
Posts: 3
Thanks: 0
Trader Rating: 0
Ireland 
Re: 899 Clutch Cable Replacement Guide

Hi Levimir
Thanks for the blown-up diagram of the Seicento clutch cable arrangement which was very helpful when added to Dr Hillman's pictures and Jamieboy's description.
Shaun
SouthOckendon.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

southockendon is offline Reply With Quote Quote 
Old 14-09-2008   #13
Join Date: Oct 2007
Location: Lancaster
Posts: 405
Thanks: 20
Trader Rating: 0
United Kingdom 
Re: 899 Clutch Cable Replacement Guide

Hello, thanks to whoever wrote this, I did the job today and the guide was really helpful.
Couple of things though, when I removed the cable from the bulkhead a washer dropped out. It is NOT the washer which goes behind the split pin as I already retrieved that. It is a similar size though and has a thicker centre, like a bush, as if it is to go into something. For the life of me I can't work out where it goes. I have everything back together now and everything seems to work but I'm worried something is going to go wrong! Anyone have any ideas please? I have to do the job again anyway as I have been supplied the wrong length cable (grrr) so would like to find its home. I can't see it in the components jpeg by the way so I wonder if it's actually nothing to do with the clutch.
Another thing is, does it matter if the hook end of the cable goes in front to back or can it come from the back so the pin is at the front? My pin was at the back but would have been so much easier if it had been at the front.

I would also like to add a little tip. When replacing the split pin you are going to drop the pin, several times, so put a length of string through the eye end, it makes it much easier than scrabbling behind the carpet for it. When the pin is in just pull the string out.

Cheers,
Ian.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

GrumpyOldMan is offline Reply With Quote Quote 
Old 28-10-2008   #14
Join Date: Oct 2008
Posts: 6
Thanks: 1
Trader Rating: 0
Re: 899 Clutch Cable Replacement Guide

Just a brief Thank you for this post.

We'd had our Cinq a day when the clutch cable went and Jamieboys guide (which is spot on I might add) gave us the confidence and know how to fix it.

Top Job many thanks.....

Darren (djh1966)
Thanks tersias thanked for this post
Dislikes tersias disliked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

djh1966 is offline Reply With Quote Quote 
Comment
Currently Active Users Viewing This Guide: 1 (0 members and 1 guests)
 
Guide Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Guide Guide Starter Category Comments Last Post
(G) Clutch cable replacement - how? Urgent help please yellow_sei Cinquecento / Seicento 23 24-11-2009 23:06
(T) guide to fit a clutch cable? benfredjosh Cinquecento / Seicento 16 19-11-2009 21:26
(T) Clutch - cable or clutch itself? SnowBord Cinquecento / Seicento 12 13-02-2005 17:18