Gear Box Selector Cables, Updated.

chumsofmanutd said:
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.
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Hi Rob, thank you for all your work on this and I’m sure that you’ll come up with a solution.
Personally I don’t understand the responses by some members, I’m grateful to you and so are many others
 
Well, my mechanic got my cables out today, and I sent these photos to cable tech, let's see what they say as to whether they are repairable (they're for the A2 1.4TDI 90BHP)
 

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Sent a further zoomed image to Cable Tech and got the response: "It looks like the outer cable has been damaged, and the wires have spread open. It would be a 50/50 chance if we could do anything with it."
 

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Dan-a2 said:
Sent a further zoomed image to Cable Tech and got the response: "It looks like the outer cable has been damaged, and the wires have spread open. It would be a 50/50 chance if we could do anything with it."
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Maybe that's the same reply WOM got when they asked.
I've asked @Clackers to send me the two gear box selector mechanism "cranks" that the swivels attach to, and the bracket that the cable adjuster fit to. I'm waiting to see if Cable-Tec can supply short sample cables, to work out what adapters are going to be required, to match the standard Cable-Tec cable to the A2 gear box.
I've started with the box end, because it's the the most complex, with swivel joints, and adjusters.This will take a while, and I am not going to post until I've got something to show, or I've thrown in the towel.
If anyone contacts Cable-Tec, please post here, to avoid crossed lines and duplication.
Mac.
 
After the realistic 50/50 chances of repair assessement from Cable Tec, I did a last search amongst car breakers, and finally found a set of the gear cables! My mechanic and I looked at them, and they seem to be the right ones. So fingers crossed it's sorted now.

Although this is sorted, I'm now concerned that after it is fixed, I'll be driving an obsolete car for which parts can no longer be easily found...
 
I've been in contact with Cable-Tec again, and they have said this:
"If we had a sample set to work with and built it, the cost for two complete cables may only be around £150 to £180 + vat and delivery"
Sounds like the way to go, is anyone going to volunteer to loan a pair of cables in good order?
Mac.
 
PlasticMac said:
I've been in contact with Cable-Tec again, and they have said this:
"If we had a sample set to work with and built it, the cost for two complete cables may only be around £150 to £180 + vat and delivery"
Sounds like the way to go, is anyone going to volunteer to loan a pair of cables in good order?
Mac.
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I would only be able to offer the damaged cables I posted photos of earlier, but clearly they are not in good order. I collect my just-fixed car tomorrow morning BTW. - I'm left wondering how many other A2 parts are no longer manufactured...
 
Dan-a2 said:
I would only be able to offer the damaged cables I posted photos of earlier, but clearly they are not in good order. I collect my just-fixed car tomorrow morning BTW. - I'm left wondering how many other A2 parts are no longer manufactured...
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Thanks, I'll pass your pics on to Cable-Tec, and see what they say.
A pair of cables in better nick, would, I'm sure, be preferable.
Surely someone out there can help?
Mac.
 
PlasticMac said:
I've been in contact with Cable-Tec again, and they have said this:
"If we had a sample set to work with and built it, the cost for two complete cables may only be around £150 to £180 + vat and delivery"
Sounds like the way to go, is anyone going to volunteer to loan a pair of cables in good order?
Mac.
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That sounds like good progress Mac, is there a minimum number of cables that they need for an order or is that a one off price?
 
Dan-a2 said:
After the realistic 50/50 chances of repair assessement from Cable Tec, I did a last search amongst car breakers, and finally found a set of the gear cables! My mechanic and I looked at them, and they seem to be the right ones. So fingers crossed it's sorted now.

Although this is sorted, I'm now concerned that after it is fixed, I'll be driving an obsolete car for which parts can no longer be easily found...
Click to expand...
Did you manage to find 8Z07118745S or did you use 8Z07118745J or N
 
PlasticMac said:
As some of us know, the gear selector cables are no longer available new. There may be a solution, as there is at least one company able to make similar cables to suit.
The problem area will be, I think the cable ends, in particular the gearbox ends.
The OEM termination is a plastic eyelet with a spherical shape centre recess, which fits into a ball on the selector mechanism. Together these make up a self aligning pivot, similar to a rose joints. It would simplify the design of the cable termination, if it could be changed to a standard readily available rose joint.
For this to be possible, the two male ball spigots to be replaced with a threaded stud, or even better, drilled out and replaced with a nut and bolt.
Is there anyone here who has any idea if such a modification is possible, and if so, could it be done by removal of the plates the male ball spigots are fixed to allow the mod? If so maybe an exchange scheme would be a runner?
Also, how accessible is the mechanism to allow such a mod?
Any information, or alternative solutions welcome, but the custom cable can only be supplied with an M6 male threaded end, so we have to work with that.
Here's a pic of the mechanism, and an example of a easily available M6 rose joint:
Mac.
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The selector end pieces are available as OE replacement parts from topran and I have used these and seem to be of reasonable quality, been running them for around 10k miles now without fault. They are Topran 116 350 and still appear to be readily available online. Possibly using these gearbox terminals on the cables can then just attach to the threaded type fittings that are used on the factory cables?

Project Commuter

Happy to collect Project Commuter up from WOM having had a whole bunch of goodies fitted. Work completed: - PTW gearbox fitted - New LUK clutch - New (used) steering rack and tie rods and end links Only done 50 miles so far but the car feels very different to drive. The gear shift throw is...
www.a2oc.net www.a2oc.net
 
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PlasticMac said:
I don't think we're quite at that point yet.
I have an offer of a loan set, so let's see what Cable-Tec say.
Mac.
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Cable-Tec have said they cannot assemble a direct replacement from their standard parts.
This was my understanding after contacting them a year ago. So I wasn't surprised.
Without modification to the gearbox bracket (where the outer terminates), and, similarly, at the tower end, Cable-Tec's standard parts cannot be used.
As I've said before, without a car to work with, figuring this out is impossible. So, I can do no more.
WOM are talking to a company that may be able to supply custom made cable sets. This is something they can do, as a business, so let's hope it goes well.
Mac.
 
Not sure if this is correct placebo ask but does anyone know the part number for TDI cables ? I have found breakers which have had an A2 so well might have the cables - but they on shelf without ID !
 
MARTYN said:
Not sure if this is correct placebo ask but does anyone know the part number for TDI cables ? I have found breakers which have had an A2 so well might have the cables - but they on shelf without ID !
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Part numbers are on the following diagram (linked parts 40 and 41) :

selector mechanism Audi A2 (A2) 2003 year Audi EUROPA 711030

selector mechanism Audi A2 (A2) 2003 year Audi EUROPA 711030 spare parts
audi.7zap.com audi.7zap.com

The variants are indicated by the part number suffix letter and then the PR-codes in the 3rd column. Note the early and late cable part numbers for the two petrol engined variants.

T60 = 3-cylinder diesel engine 1.4 L unit 045.D
T0U = 3-cylinder diesel engine 1.4 L unit 045.B
T1Q = 4-cylinder gasoline engine 1.4 L unit 036.D (aluminum)
T94 = 4-cylinder gasoline engine 1.6 L unit 036.N

Tdi is therefore suffix "S"

If you do find a pair of cables - can you photograph / measure them and then add here with their part number?
 
Hello all, just wondering if anyone got anywhere with the cable replacements? My A2 has been sitting on the drive for 6 months with the cables out while I try find some more. Does anyone know of a second hand pair of cables for a 2002 1.4tdi?
 
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