PlasticMac
Member
Oh, OK I'll bow out.
Mac.
Gear Box Selector Cables, Updated.
- Thread starter PlasticMac
- Start date
Mac.
PlasticMac
Member
It is, however, important that A2 Owners have access to these cable sets, regardless of whether they are WOM customers or not.
Mac.
PlasticMac
Member
It would have been nice if you'd let me know you were already on the case when we discussed it during Saturday's End of Season Meal.
I would not have wasted my time contacting Cable-Tec and posting their reply, had I known.
Mac.
chumsofmanutd
A2OC Donor
I did Mac, sorry for any confusion or if you missed that bit of the conversation. Of course, any solution will be for the benefit of the whole community, lets just hope we can find one
Cheers
Rob.
Rickmeister
A2OC Supporter
I have just done a drive by through this thread and its great to see a UK centric solution being worked up.
However, I am coming across from Germany in a car in Dec (see the Volico group buy thread), so if you are stuck or WOM want a few for stock, then check AT and I can bring some across for you.
However, I am coming across from Germany in a car in Dec (see the Volico group buy thread), so if you are stuck or WOM want a few for stock, then check AT and I can bring some across for you.
Hi All. Just joined the forum because... my garage says my A2 1.4TDI 90BHP 2005 needs a new gear cable kit (8Z07118745S)... It's been stuck in 2nd gear since 6th November as we can't find any I actually did contact Cable-Tec, and they said they would try to repair cables (not supply new ones) and I should send photos of the old ones to assess condition. Am currently waiting for garage to extract them. Obviously I'd be grateful for any news on developments with new cable manufcature or advice etc. Thanks.
I actually did contact Cable-Tec, and they said they would try to repair cables (not supply new ones) and I should send photos of the old ones to assess condition. Am currently waiting for garage to extract them. Obviously I'd be grateful for any news on developments with new cable manufcature or advice etc. Thanks.
PlasticMac
Member
This thread didn't move on from the idea that standard cables, from someone like Cable-Tec could be adapted to provide replacements,bat a reasonable cost, quite possibly favourably comparable to the Audi originals.
To move the idea forward, needed someone with a car in front of them, to figure out what adaptors would be required. That never happened.
Last Saturday evening, I was speaking to one of the guests at the End of Season Meal, who enquired on progress. I said it needed someone like WOM to take that on. At the time, I had no idea I was speaking to Rob (aka @chumsofmanutd).
The reply I got from Cable-Tec, which I posted yesterday, along with renderings of a possible way forward are very encouraging, and WOM's involvement is even more so.
For what it's worth, I don't think repair/refurb of original cables being anything other than a very temporary solution.
for a positive update from Rob.
Mac.
To move the idea forward, needed someone with a car in front of them, to figure out what adaptors would be required. That never happened.
Last Saturday evening, I was speaking to one of the guests at the End of Season Meal, who enquired on progress. I said it needed someone like WOM to take that on. At the time, I had no idea I was speaking to Rob (aka @chumsofmanutd).
The reply I got from Cable-Tec, which I posted yesterday, along with renderings of a possible way forward are very encouraging, and WOM's involvement is even more so.
For what it's worth, I don't think repair/refurb of original cables being anything other than a very temporary solution.
for a positive update from Rob.Mac.
audifan
A2OC Donor
So I wasted even more of my time stating the important areas of the cables, detail pictures of a set with the gear stick attached. also stated that I had looked at other cables but none the same as the A2 and the fact that Audi produced 3 different cable sets for the A2. Where was WOM at the start of this????
George Hogg
A2OC Donor
I’m not sure what your point is. But surely it is great to see this moving forward positively. Of course your input has been very informative Goodness
I'm very grateful for the diagrams and link to workshop manual. I'm unsure of the quality of the garage I've given my car to, so at least I have some background info with this
dj_efk
A2OC Donor
I’d be interested in purchasing a set as spares for future-proofing.
chumsofmanutd
A2OC Donor
@audifan , I'm sorry if you think I should have found this thread earlier.
Just to clarify, we realised that there is a need to explore solutions to gear cable issues on the A2 for a while. However, up until last week we hadn't learnt anything notable or engaged with Cable Tec or anyone else to discuss solutions to the issue. We have been keeping vehicles on the road either by using new 'old stock', OEM Audi units or good used units from some of our fantastic reputable breakers, shout outs @A2Steve & @Clackers!
Last week we had a forum member drop a vehicle off with a more unusual failure mode of the gear cables. Most of the time we seem to find the cables stiffen up making changing more challenging but still possible, however in this instance without any warning or notable deterioration of changing gear, a cable had snapped and left the vehicle immobile.
With good used cables becoming ever more difficult to locate, we saw this as an opportunity to explore alternative options. A quick online search last week identified Cable Tech as a possible specialist in the area. After a brief exchange of messages, they requested we send a broken set of cables to them to explore solutions. We proceeded to send these as requested late last week and from one of our other vehicles we also included an A2 gear lever, the mounting bracket for the gearbox end and the adjustable rose joints to help them explore viable solutions.
During some rare spare time last Friday evening, prior to the fantastic social on the following evening I stumbled across this thread and saw that @PlasticMac had already been in contact with Cable Tec re. this issue. This was news to me, Cable Tec had not mentioned this but they are a fair sized firm so I guess that can be expected.
Having received the cables and related items, Cable Tec have come back to us during the last couple of days. The good news is that they have managed to repair the cables we sent in this instance but as aforementioned, this was a more unusual failure mode of the cables. On this example, the end fitting had come away from the outer casing, this enabled them to cut the old inner cable out, and push a new one through.
So, good news on this occasion. Cable Tec have advised they are happy for sets of cables to be sent in (to their Northern branch) and will do their best to carry out similar repairs but it all depends on what has broken on the original cable as to whether that is possible. Whether or not similar repairs to solve the common stiff change symptom are viable remains to be seen but we do intend to send them other sets when we have them to see what can be done.
With regards to manufacturing replacement sets including alternative options using cables that do not rely on plastic parts and use a more standard alternative mounting with nuts and washers:
The feedback was not as positive. The main issues are apparently quite common on a lot of OEM gearshift cables - plastic moulded parts that are mass produced in the first instance and now not available. After inspection, it also became apparent that parts of the brackets & rubber mountings are actually crimped into place on the outer casings of the A2 Cables. This is very unusual, as usually they just slip off the cable and can be re-mounted onto new casings.
So, they have ruled themselves out of manufacturing replacement cables. They have however mentioned that they use a quality manufacturer for similar complex cable solutions located over seas. They have sent over some information and pictures to them on our behalf to see if it is something they would be able to help with. It however remains to be seen whether issues such as minimum order quantities may prove to be problematic.
I hope that all helps to shed more light on the situation for everyone, well done everyone for their contributions to the thread.
Cheers
Rob.
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PlasticMac
Member
So, is it your belief that there no way the standard cables, that Cable-Tec can, I believe, supply, at custom lengths, but with standard ends, having suitable terminations added to suit the A2 (and other VAG cars)? These terminations would be either off the shelf, or made within the club, (most likely a mix of both),
Having now read through the thread, you'll have got the gist.
Mac.
Having now read through the thread, you'll have got the gist.
Mac.
k7aus
Member
Ive checked and cannot find anywhere in EU that can supply 8Z07118745S as either brand new or used ive tried Ebay de and ebay de classifieds - But thank you for the offer.
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k7aus
Member
Surely as a business is WOM responsibility to be reactive to their paying customers wants and needs and not be at the end of keyboard monitoring forum questions and answers. If a solution comes about by research and investigation on customers cars, then posting that information will be beneficial to all, and from above this has happened. I dropped the car off on the 14th Nov 2022, but had previously looked at your Jan 2022 posts and pictures and found them informative and helpful.
audifan
A2OC Donor
Further to this can Cable-Tec just supply suitable inner cables that have the correct fittings for the gearstick and the thread to take the plastic joints at the selector end. At least this way the outer cable that has all the fitting points would not be needed. A half way but acceptable solution as removing the cables from the car is a PITA as is the bulkhead fitting and grommet. Remember that Audi produced three part numbers for these cables so assume that three different lengths of cables may be needed?
chumsofmanutd
A2OC Donor
Thank you very much for the offer but I as @k7aus mentions, I don't believe AT have any stock left.
Mac & Audifan, we are due to have further dialogue with Cable-Tec to clarify some more queries we have including what exactly they are able to supply and try and explore other solutions, maybe by combining different suppliers. I think if I've understood correctly, at least the basic cables are available, its more of a case of how the fittings are secured to the cable that is the challenging part. We also believe modification to the cable mounts on the vehicle side will be required in addition to the mounts on the cable itself for any alternative solution to the original.
We haven't given up on this, we believe a solution will be possible but I think Cable-Tec's reluctance to produce a solution as experts in the field, who were originally positive about alternative suggestions of terminations etc gives an idea of the challenges involved.
We'll update with any progress in due course as and when time allows.
Cheers
Rob.
George Hogg
A2OC Donor
Thanks for all your work on this Rob, it’s much appreciated!
PlasticMac
Member
From the beginning of this thread, Cable-Tec made it clear that they could only supply cables with standard terminations, (M6 inner, M10 outer from memory), but the length of both inner and outer were custom, as required, no reluctance at all. They have been helpful, as the rendering from them, which I posted recently shows.
Rob, ( @chumsofmanutd ) I'm guessing that your workload ("in due course as and when time allows") makes it unlikely that you'll be able to provide the time consuming prototype help I described last Saturday. I understand that.
So it's down to A2OC members to try.
I think we're back to needing a car in no rush to be back on the road, a willing and patient mechanic, and a four Cable-Tec standard cables, each being one end, like a cable that's been cut 6" from the end. With this, the aim would be to work out what was needed to adapt the Cable-Tec outer to the gear box and tower, and the Cable-Tec inner to the moving mechanism.
As I've said from the beginning I'll do all I can to help, but my spannering days are over. I'll order the four "samples" from Cable-Tec, and pay for them, and prepare the sketches for any A2 specific adaptors, so that machining them can be investigated, and identify suitable swivels etc to fit.
Once this (not inconsequential) task is done, the lengths of the outers and inners can be measured. With luck, since all A2 engines seem to have very similar mechanisms, once we have the lengths for one type, the only differences to the rest will be in the lengths.
Unless something like I've described happens, there will be a lot of very sad A2OC members.
I'll take a rest from this thread, while others comment, and possibly come up with practical alternatives.
Fingers crossed for the footy tonight.
Mac.
chumsofmanutd
A2OC Donor
Hi Mac,
Just to be clear, I do not think Cable-Tec have been unhelpful, far from it. I was merely pointing out that having this week had the opportunity to physically study the cables and relevant items, they were unable to offer a full working solution. Prior to seeing them they were much more positive about being able to do this but the cable arrangement proved to be more complex than they had initially expected. This just helps to put some context on the task in hand.
As mentioned, we have not given up on it and intend to come up with a solution through one means or another.
Enjoy the football.
Cheers
Rob.
Just to be clear, I do not think Cable-Tec have been unhelpful, far from it. I was merely pointing out that having this week had the opportunity to physically study the cables and relevant items, they were unable to offer a full working solution. Prior to seeing them they were much more positive about being able to do this but the cable arrangement proved to be more complex than they had initially expected. This just helps to put some context on the task in hand.
As mentioned, we have not given up on it and intend to come up with a solution through one means or another.
Enjoy the football.
Cheers
Rob.