Gear Box Selector Cables, Updated.

PlasticMac

PlasticMac

Admin Team
United-Kingdom
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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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.
Click to expand...
2006 Merc Sprinter cables have a plastic threaded end to the bowden cable with an adjustable snap lock adapter that presses onto the ball on the selector lever

Will compare dimensions when next in workshop
 
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.
Click to expand...

If I've not misunderstood your question, I think this answer is possibly straightforward within the VAG catalogues.

First thing if I've understood my reading is that the ball spigoted parts were variants of similar 1J0 parts in the early TT / VW Golf IV and other cars of that generation : for instance, the counterweighted cable-end for the TT and A3 uses a different clip-on cable end that goes over a cylindrical shaft on the bell crank and shifter casting in place of the ball stud and is held in place with a circlip (if I remember correctly). The TT's one has a slightly smaller diameter of the casting to give a shorter shift (this is used by some people to get a sportier shift, possibly in Golf circles) ; I believe there are contemporary pieces from less overtly sporting VAG models that would give a similar shifting length to the A2 but with the newer connector end, but you need to really work on the catalogues to find the exact part number.

8N0711051A / 1J0711051Q is one part number that comes to mind for this.

There is also a custom piece from Forge motorsport -

www.forgemotorsport.co.uk

Audi, VW, SEAT, and Skoda 6 Speed Adjustable Quick Shifter | FMVWQS | Forge Motorsport

To check if the component is compatible with your gearbox, the OEM shifter part number should have the code 8J0 711 046 E embossed on...
www.forgemotorsport.co.uk www.forgemotorsport.co.uk

Secondly, for the bell crank that gives across-the-gate shifts by raising / lowering the selector in and out of the box, again there are bell cranks from other VAG models that have clip-secured ends.

selector mechanism; for vehicles with shift cable Ibiza/ST (IB) 2000 year Seat EUROPA 711030

selector mechanism<br/>for vehicles with shift cable Ibiza/ST (IB) 2000 year Seat EUROPA 711030 spare parts
seat.7zap.com seat.7zap.com

Is this close to the idea you were thinking of?
 
Robin_Cox said:
If I've not misunderstood your question, I think this answer is possibly straightforward within the VAG catalogues.

First thing if I've understood my reading is that the ball spigoted parts were variants of similar 1J0 parts in the early TT / VW Golf IV and other cars of that generation : for instance, the counterweighted cable-end for the TT and A3 uses a different clip-on cable end that goes over a cylindrical shaft on the bell crank and shifter casting in place of the ball stud and is held in place with a circlip (if I remember correctly). The TT's one has a slightly smaller diameter of the casting to give a shorter shift (this is used by some people to get a sportier shift, possibly in Golf circles) ; I believe there are contemporary pieces from less overtly sporting VAG models that would give a similar shifting length to the A2 but with the newer connector end, but you need to really work on the catalogues to find the exact part number.

8N0711051A / 1J0711051Q is one part number that comes to mind for this.

There is also a custom piece from Forge motorsport -

www.forgemotorsport.co.uk

Audi, VW, SEAT, and Skoda 6 Speed Adjustable Quick Shifter | FMVWQS | Forge Motorsport

To check if the component is compatible with your gearbox, the OEM shifter part number should have the code 8J0 711 046 E embossed on...
www.forgemotorsport.co.uk www.forgemotorsport.co.uk

Secondly, for the bell crank that gives across-the-gate shifts by raising / lowering the selector in and out of the box, again there are bell cranks from other VAG models that have clip-secured ends.

selector mechanism; for vehicles with shift cable Ibiza/ST (IB) 2000 year Seat EUROPA 711030

selector mechanism<br/>for vehicles with shift cable Ibiza/ST (IB) 2000 year Seat EUROPA 711030 spare parts
seat.7zap.com seat.7zap.com

Is this close to the idea you were thinking of?
Click to expand...
Yesss... but we don't, need to use VAG bits, as they may, (probably will), go the same way as our's has already, and then we'd have to do it all again.
VAG prices are much higher than industry standard parts too.
Mac.
 
I asked CableTec to give me an indication of cost per cable.
A cable of 1 mtr length, plain M6 threaded ends, without swivels/eyelets, will cost around £50 - £60 each (£100 - £120 per pair).
When I have more information, lengths, ball and spigot diameter etc, I'll be able to estimate the cost of the terminations. Swivel joints, in plastic or metal are readily available, and, at a guess, the cost, per cable, will be in the range of £10 - £15.
Mac.
 
I think a metal rose joint may be too much precision. The plastic is light and moves easily and is specific to allow the cables to be quickly set up and adjusted. The rose joint would have to be adjustable to set the cables correctly.
Great if we can get replacement cables to take the standard Audi fittings. I would have thought there is more of an issue with the gearstick end of the cables.
 
audifan said:
I think a metal rose joint may be too much precision. The plastic is light and moves easily and is specific to allow the cables to be quickly set up and adjusted. The rose joint would have to be adjustable to set the cables correctly.
Great if we can get replacement cables to take the standard Audi fittings. I would have thought there is more of an issue with the gearstick end of the cables.
Click to expand...
Cheers @audifan
Plastic swivel, and rose joints are easily available, and not expensive, but I need to know the ball diameter. As to the lever end, I don't have any really useful info. Any contribution very welcome.
Mac.
 
Mac exactly what information are you needing to progress this?

Just checked Audi A1 cables are longer than the A2 cables.
 
There appears to be three important areas on these cables. One the rigid outer tube and plain straight inner that fits through the base and onto the gearstick. Two the mounting brackets that secure the cables to lock the outers from moving near the selector tower. Three the gearbox ends that are spring loaded with locking rings to enable quick and accurate cable adjustments to be made.

Have had a look at a current Audi A1 set up and although the gearstick end is very similar the overall length of the cables is longer on the A1 but are also secured by brackets near the selector. Do not know if the A1 cables can be adapted by getting the bracket locations to coincide and perhaps just let the extra length curve around. Also not checked if the A1 cables will lock onto the A2 ball ends.

If I have some time I will try to take some pictures.....
 
My idea was to produce a new cable, all new parts, and a (very tough) guide price of around £60 each.
The cable itself, from CableTec, will be the most straight forward, I think, but the final dimension, particularly of the inner, will depend on the dimensions of the swivel/rose joint ends.
So first job is to get accurate details of each end. I have not seen a cable in real life, and am not keen to start taking my car apart to find out, so I need the diameter of the ball at the gearbox end, and, if I have it right, the diameter of the pillar at the gear lever end. This will enable me to choose a suitable, new, probably plastic, alternative.
As I see it, we have to go one step at a time, as the dimension of one part are dependant on others.
If anyone can send me a cable (in any condition, within reason) it will help to understand how the outer cable from CableTec will allow adjustment.
As supplied by CableTec, the outer termination looks like this (M6):

cabletec outer end m6.png

Mac.
 
Looking at that picture that only looks like a fixing point and not adjustable. The adjustment on the audi cables is by moving the spring loaded ball ends where they fit on the inner cable threaded ends.

No idea what the cost of Audi cables were.

One problem I can see is the rubber sealing boot that fits the bulkhead would somehow have to be swapped from the old cables to the new.
 
Does the bulk head sealing boot come with each new cable from Audi?
The inner, from CableTec, is also threaded M6 at both ends.
Mac.
 
Looking at it then I would have to say they fit the boot then build the ends of the cables. On the A2 the cables were a set - probably for this very reason. Other cars each cable is available separately. When I get a chance will post some pictures of the A2 cables to give a better idea of what is involved.
 
audifan said:
Looking at it then I would have to say they fit the boot then build the ends of the cables. On the A2 the cables were a set - probably for this very reason. Other cars each cable is available separately. When I get a chance will post some pictures of the A2 cables to give a better idea of what is involved.
Click to expand...
We'll have to work around some things, and the bulkhead grommet looks like one. We're not going to get a perfect replica.
I'm sure other parts will go the same way.
We may be able to cut the end off the faulty cable, and pull it through. The new cable may well then fit, before the end fitting has been attached.
Mac.
 
PlasticMac said:
Out of interest, what was the cost of the genuine Audi cables, when they were available?
Mac.
Click to expand...
Hi Mac,

I'm a fan of online-tele.com, seems to to be a kind of the German TPS, but prices very similar to Audi, the point being you can normally get at prices of NLA parts. With part number 8Z0 711 874S (correct?????) picked up from an older thread in their search box the part comes up as NLA, click 'Details' and then click (bizarrely) 'Print article data sheet' you finally get...

1643481666346.png


Hope it helps.

Andy
 
Andrew said:
Hi Mac,

I'm a fan of online-tele.com, seems to to be a kind of the German TPS, but prices very similar to Audi, the point being you can normally get at prices of NLA parts. With part number 8Z0 711 874S (correct?????) picked up from an older thread in their search box the part comes up as NLA, click 'Details' and then click (bizarrely) 'Print article data sheet' you finally get...

View attachment 90598

Hope it helps.

Andy
Click to expand...
Thanks Andy.
It seems possible that the price for an approximate alternative will be significantly less than the (discontinued) Audi part. ?
Mac.
 
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