Berlingo clutch cable woes

[waddycall]

any Berlingo experts here? My 06 1.9d berlingo has been through 4 or 5 clutch cables since I got it in 2012. It went again today. Each time I’ve had one of the local garages do the work. Last time (around 10 months ago) I was told I needed a complete clutch to put it right. When I picked the van up I was told all sorts of stuff about how the previous garage had done the clutch all wrong and that was why it was eating cables and it should be fine now as they’d done the job right. It’s always the very end of the cable that snaps where it goes into the arm. I’m thinking that maybe there’s a sharp bit on the arm and poor alignment but would be interested to hear if anyone knows of this happening on other berlingos.
Cheers.

 

[brightspark]

any Berlingo experts here? My 06 1.9d berlingo has been through 4 or 5 clutch cables since I got it in 2012. It went again today. Each time I’ve had one of the local garages do the work. Last time (around 10 months ago) I was told I needed a complete clutch to put it right. When I picked the van up I was told all sorts of stuff about how the previous garage had done the clutch all wrong and that was why it was eating cables and it should be fine now as they’d done the job right. It’s always the very end of the cable that snaps where it goes into the arm. I’m thinking that maybe there’s a sharp bit on the arm and poor alignment but would be interested to hear if anyone knows of this happening on other berlingos.
Cheers.

i had 3 cables go on 2 partners and 2 were under warranty .the automatic adjusters collapsed on mine

 

[The_Yellow_Ardvark]

New clutch.
The PTFE bush in bell housing let's go.
VW golfs and polo's do the same.
Do the clutch and cable you will be OK.



Have a look at the pedal bushes. They can give the same issue.

 

[pedrobedro]

If the nipple is not rotating in the clutch arm it will break off because the cable flexes. Can you look at the end while someone presses the pedal ?

 

[waddycall]

New clutch.
The PTFE bush in bell housing let's go.
VW golfs and polo's do the same.
Do the clutch and cable you will be OK.



Have a look at the pedal bushes. They can give the same issue.

The clutch has been renewe twice. Last time about ten months ago. Is it likely that the bush would go so soon? By the way I know nothing about clutches.

 

[gordon stephenson]

Cortinas years ago suffered the same, snapping the eye off the cable at the pedal end. Trouble was the rough pedal hook was not letting the eye swivel to maintain a straight pull, smooth and grease the pedal hook and all was cured.

 

[Turbo]

I had a woefully heavy clutch in my 306, which I think is the same gearbox. A new good quality clutch cable helped a lot but what made the biggest difference was replacing the nylon bushes in the bell housing that the clutch arm pivots on. They are only a few pence from the dealer but you need the box out to replace them. Also make sure they clean the rust off the clutch arm & grease it otherwise you nylon bushings will not last long!

 

[Eric the chicken]

I had a woefully heavy clutch in my 306, which I think is the same gearbox. A new good quality clutch cable helped a lot but what made the biggest difference was replacing the nylon bushes in the bell housing that the clutch arm pivots on. They are only a few pence from the dealer but you need the box out to replace them. Also make sure they clean the rust off the clutch arm & grease it otherwise you nylon bushings will not last long!

any Berlingo experts here? My 06 1.9d berlingo has been through 4 or 5 clutch cables since I got it in 2012. It went again today. Each time I’ve had one of the local garages do the work. Last time (around 10 months ago) I was told I needed a complete clutch to put it right. When I picked the van up I was told all sorts of stuff about how the previous garage had done the clutch all wrong and that was why it was eating cables and it should be fine now as they’d done the job right. It’s always the very end of the cable that snaps where it goes into the arm. I’m thinking that maybe there’s a sharp bit on the arm and poor alignment but would be interested to hear if anyone knows of this happening on other berlingos.
Cheers.

 

[Eric the chicken]

Know nothing of Berlingos, however some years ago my 1100 BMW gs with 98,000 miles on began to break clutch cables every 10,000 miles or so. At 120,000 miles it happened again. I checked the run of the cable and realised the clutch cable lever had worn the fixed part of the lever on the handlebar to the point where the lever was twisting as it was pulled in until it caused premature failure. New clutch lever assembly solved the problem. Bike is now on 145,000 with no further problems. So can I suggest checking the run of the actuating lever and associated components?

 

[zeppelin builder]

with diapraghm spring clutches the pedal operation gets heavier as the clutch wears as the spring can no longer collapse it has to be pushed inward . had it with peugots before