Clutch cable VAZ 2109 old and new model differences: Clutch cable VAZ 21083, 21093, 21099

Author: Ivan Baranov

Replacing the VAZ 2109 clutch cable is required if it breaks. Signs that the cable needs to be changed are the appearance of clicks when squeezing the clutch pedal (CP), the pedal falls down and does not rise back, and problems arise in controlling the clutch. The article provides detailed instructions, thanks to which any car enthusiast can change the clutch cable on a VAZ 2109. In addition, a video is attached that clearly shows the entire process.

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Clutch cable VAZ 21083, 21093, 21099

The clutch drive of VAZ 21083, 21093, 21099 cars is not dismountable, without gaps, and is carried out using a cable.
How the clutch cable works for VAZ 21083, 21093, 21099

See photo at the beginning of the article.

Multi-core steel clutch cable. At one end of the cable there is an eyelet for attachment to the clutch pedal, at the other there is a leash for attachment to the fork lever. The part of the cable in front of the leash is covered with a rubber corrugated protective cover.

The cable moves in a metal sheath coated with polyethylene. The shell has an upper tip with a rubber buffer (for installation and abutment in the hole on the engine compartment shield) and a lower tip with an adjusting clutch drive unit (a piece of thread with an adjusting nut, lock nut, bushing and washers).

Clutch cable length is 76 cm.

Weight - 360 gr.

Where and how is the clutch cable installed on the VAZ 21083

The clutch cable is stretched from the pedal assembly of the car (attached to the clutch pedal) to the clutch fork lever on the gearbox housing.

Fastening the drive cable to the clutch pedal of VAZ 21083, 21093, 21099

At the same time, it passes through a special hole in the front shield of the engine compartment.

Leash and adjusting unit for clutch cable VAZ 21083, 21093, 21099

The lower end of the clutch cable sheath is mounted on the gearbox housing bracket. The cable itself is connected to the clutch release fork lever using a leash.

How does a clutch cable work?

When you press the pedal, the clutch disengages. In this case, the drive cable is tensioned, the fork moves the release clutch (release bearing), which presses on the “basket” pressure spring, its petals move, moving the drive disk away from the driven one. A gap appears between the working surface of the flywheel and the driven disk linings. The transmission of torque from the engine to the gearbox is interrupted. At this moment, the driver can engage one or another gear.

When the clutch pedal is released, the cable returns to its original position. the clutch engages.

Read more: “Design and principle of operation of the clutch of VAZ 2108, 2109, 21099 cars.”

Clutch cable malfunctions

Separation of the cable end

Due to the poor manufacturing quality of the part on VAZ 21083, 21093, 21099 vehicles, separation of the cable tip is one of the most common clutch malfunctions. It is not advisable to repair the cable after this. Needs to be replaced with a new one.

Fracture of the cable inside the sheath

The cable begins to jam inside the shell, as a result the clutch operates jerkily and does not engage completely (slips). The only way to correct the situation is to replace the cable with a new one or a functional used one.

Details about replacing the cable: “Replacing the clutch cable of VAZ 2108, 2109, 21099 cars.”

Applicability of the clutch cable on VAZ 21083, 21093, 21099 vehicles

VAZ 2108, 21081, 21083, 2109, 21091, 21093, 21099 cars are equipped with a clutch cable with catalog number 2109-1602210-10 or its analogues from different manufacturers, but with identical parameters.

Notes and additions

An extended clutch cable 21086-1602210-10 was installed on a VAZ 21086 car with right-hand drive (export version).

More articles on the clutch of VAZ 21083, 21093, 21099 cars

Adjusting the clutch VAZ 21083 (21093, 21099) Main malfunctions in the operation of the clutch The clutch is driven by the VAZ 2108, 2109, 21099, reasons

Reasons for replacement

Typically, on a VAZ 2109, replacing the clutch cable is necessary if:

• The clutch is not working properly. That is, it is difficult for the driver to press the clutch pedal, as a result of which the car is difficult to start.
• The gearbox is also acting up. In addition to the fact that it is difficult to switch, it also makes sounds that are not entirely understandable during its operation.
• The clutch pedal has fallen down and does not return to its original position.

Note: however, these “symptoms” may indicate the presence of other problems, so a complete diagnosis of the car is necessary.

Replacing the clutch cable of a VAZ 2109

Note: It is better if the cable breaks rather than the fork breaking. Indeed, in some cases, the pedal fails due to a faulty fork, and replacing it costs much more than replacing a cable (a new cable costs about 200 rubles, and a new fork costs about 2000 rubles)

Replacing the clutch cable on VAZ 2108, 2109, 21099 cars

Such malfunctions in the clutch operation as “the clutch is moving” and “the clutch is slipping” can happen due to a failed clutch drive cable (it is pulled out or frayed and stuck in the sheath).

In addition, a faulty clutch cable can cause the clutch to completely fail to operate (for example, a broken cable tip). On VAZ 2108, 2109, 21099 cars this is one of the most common malfunctions. In any case, the faulty clutch cable must be replaced.

Procedure for replacing the clutch cable

Remove the old clutch cable.

Disconnect the end of the cable sheath from the bracket on the clutch housing

To do this, loosen the tightening of the nut (lock nut) securing the end of the cable sheath to the bracket (you will need two 17mm wrenches). And remove the tip of the cable sheath from the slot in the bracket.

Disconnect the cable lead from the clutch release fork lever

Disconnect the cable end from the clutch pedal

To do this, use pliers to pull out the spring retaining bracket from the pin on the pedal and remove the cable tip. There is a polyethylene sleeve on the finger; if possible, do not lose it.

We remove the clutch cable through the hole in the front panel of the engine compartment

Installing a new clutch cable.

The cable is installed in reverse order

It is threaded through a hole in the shield, the tip of the cable is attached to the pin on the pedal, the leash is hooked onto the fork lever, the tip of the sheath is inserted into the slot on the bracket and secured with nuts.

After installing a new clutch cable, it is necessary to adjust its tension (See “Adjusting the clutch drive”).

Notes and additions

According to the technical regulations on VAZ 2108, 2109, 21099 vehicles, periodic checks and maintenance of the clutch drive are carried out once every 30,000 km, but it is recommended to reduce this interval to once every 15,000 km.

More articles on the clutch of VAZ 2108, 2109, 21099 cars

— Jerks when the clutch operates

— Checking the clutch on VAZ 2108, 2109, 21099 cars

— Design and principle of operation of the clutch of VAZ 2108, 2109, 21099 cars

— Malfunctions in the clutch operation of VAZ 2108, 2109, 21099 cars

— Jerks when the clutch operates

Progress

1. Loosening of the fastening of the vehicle mounting bracket to the box.
2. Removing the lower part of the cable from the clutch release fork.

So, a start has been made, and now we need to return to the salon. The following work is performed here:

1. Disconnecting the cable from the pedal. To do this, you need to remove all the floor mats from the interior.
2. Removing the lock washer. To do this you will need an ordinary minus screwdriver. Next, the pin connecting the part to the bracket is removed.
3. Now you can get the cable itself. There is a special rubber cushion in the engine compartment, and under the steering wheel there is a hole through which the shell will need to be removed. We press on the pillow, remove the shell and remove the old element.

Dismantling work has been completed. Now we move directly to the procedure for installing a new vehicle. Installation begins from the interior. This is done as follows:

1. We insert a new cable into the hole, mount its end on the pedal, and secure it with a lock washer.
2. We secure the vehicle in the box. This must be done in such a way that the bushing is located on the bracket. Then the thread will be reliably protected.
3. We insert the end of the cable into the fork. Here you can lubricate the cable with oil.

The last step is adjusting the pedal. Under it there is a special nut that needs to be removed. Immediately below it there is a lock nut that is tightened. Then we return the first nut to its place and place the rubber washer on the fork

Please note that the brake and clutch pedals must be at the same level. Otherwise, the clutch pedal will wear out much faster.

How to replace a VAZ clutch cable. Do it yourself!

Replacing and adjusting the clutch cable on a VAZ 2108, VAZ 2109, VAZ 21099

Welcome! Today in this article we will look at the correct replacement of the clutch cable. And also after replacing the cable with a new one, we will describe in detail the steps by which you can adjust this clutch cable.

Summary:

Where is the clutch cable located? Part of the cable is located inside the car, that is, to be more precise, it is connected to the clutch pedal. And the second part of the cable is located on the left side of the engine compartment, for clarity, see the photo below:

Note! The cable, as you already understand, is indicated by three red arrows!

• The arrow under the number “1” indicates the place where the cable continues to move immediately after exiting the hole in the front part of the body.
• And the arrow numbered “3” shows the place where the tip of the cable sheath is screwed to the bracket.

When do you need to change and adjust the clutch cable?

It must be replaced if: • It breaks, if it is deformed and for other reasons that will also be associated with the cable.

Note! Before the cable breaks, it will begin to make various sounds by which you can determine that the cable already needs to be replaced, and the sounds will be like crackling, crunching, etc.

It is subject to adjustment if: • The clutch pedal moves incorrectly, that is, if the pedal moves too little or too much, which does not correspond to the norm.

• It also needs to be adjusted if the clutch pedal is located at a different level with the brake pedal, which also does not correspond to the norm.

How to replace the clutch cable on a VAZ 2108-VAZ 21099?

Removal: 1) First, using two wrenches, loosen both nuts that secure the cable sheath to the bracket.

2) After this, slightly lift the cable with your hand and remove it from the socket.

3) Next, disconnect the clutch cable lead (Indicated by the red arrow) from the release fork (Blue arrow).

4) When the cable is disconnected from everything in the engine compartment, then go into the car interior, and then use a screwdriver to pry the pedal pin bracket and then remove it.

5) Now disconnect the upper end of the cable from the pedal pin.

6) And as a result, going back to the engine compartment, pull the clutch cable out through the front panel.

Installation:

Note! The new clutch cable is installed in the reverse order of removal. But just below we have specially prepared instructions on how to install a new clutch cable!

1) In the same way, first insert the new cable through the holes in the shield.

2) After this, in the cabin, install the upper end of the cable on the pedal pin, and secure the whole thing with a locking bracket.

3) In the engine compartment, first place the cable lead on the fork. Then insert the cable between the bracket and then tighten both nuts securing the tip of the cable sheath.

Note! After completing the operation, adjust the clutch cable!

Clutch cable adjustment:

Use two wrenches to make adjustments. Using them, loosen both nuts that secure the end of the cable sheath. And then, by rotating these nuts, tighten the cable so that the clutch pedal travel is “125–135 mm”, and so that it is flush with the brake pedal.

Additional video materials: Would you like more details about replacing and adjusting the clutch cable? If yes! Then, in this case, we have prepared a short video for you, after watching it, you will have no questions left.

Note! Well, if you still have questions, then ask them in the comments and our employees will answer them as soon as possible!

Design and principle of operation of “e-gas”

By default, an electronic pedal consists of: an electronic damper, the pedal itself, and a chip sensor on the pedal itself. The operating scheme is as follows: when you press the accelerator, the electronic sensor amplifies the signal and transmits it to the electronic control unit (ECU), which indicates to the damper the degree of opening or closing.

But sometimes these transitions can't always keep up with the software. In this regard, sensors often produce “correlation violation” errors. There are two ways to cure the problem of “dampness” in the system:

A complete replacement of the chip board with a re-flashed (unlocked) one with the ability to set modes “for yourself” and regulate emissions into the atmosphere yourself. As a rule, in such situations, drivers return to Euro-2 standards

and increase engine power by 15-20% plus;

The electronic gas pedal on the VAZ 2114 is replaced with a similar new one, but the chip remains the same - not hacked, which means it will not break again for the first time.

E-Gas (electronic gas pedal) is an electronic gas pedal that replaced the cable-operated throttle valve. Email The gas pedal controls the throttle electronically rather than physically. AvtoVAZ began producing models with E-Gas at the beginning of 2011, the reason was the environmental standards Euro-4 and Euro-5, which must be observed.

Clutch cable VAZ Lada 2108 old model Autopartner

China supplies automatic clutch cable 2109-1602210 2109-1602210-10 2109-1602210-11

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Checking the clutch cable | How does a car work?

Typical clutch cable

A typical cable-actuated clutch on a front-engine vehicle. Some cars have hydraulic clutches.

Grip The cable has an inner core of steel wire that slides inside the outer sheath. It should last at least two years, but check it at every major service; if it breaks, it can do so without warning.

The heavy clutch pedal pressure required for operation can mask any initial stiffness or stickiness of the cable itself. The exposed ends of the cable are the parts most likely to wear out and break, especially on the transmission side.

To check or replace the cable, place the car on a ramp or stand the axle and place wheel chocks on the ground.

Clutch types

This may be a fork that is turned on the pedal by a pin held in place by a cotter pin.

The cable may end in a loop that fits onto the hook of the pedal. This could be a hole in a keyhole.

Cable check

Disconnect the cable from the gearbox side. It is attached to the clutch switch. lever with nuts, which also provide adjustment.

Move the clutch pedal manually. You should feel if the cable glides smoothly. Otherwise, the cable may be bent at too sharp an angle due to improper routing.

There are usually guides to allow the path to curve smoothly. Make sure the outer casing is not kinked or broken: if so, replace the cable.

If the cable needs lubricant, apply it to the inner cable at each end and slide it back and forth.

Pay special attention to the cable on a rear-engine vehicle, as its long path makes it more susceptible to damage.

Inspect the exposed ends of the inner core, pulling on each end to expose as much as possible. If just one wire breaks, others will soon follow: replace the cable immediately.

If the cable passes all tests, reconnect the transmission end and adjust the nuts until the correct free play is achieved (see Clutch Adjustment).

Finally, tighten the locknut.

Cable replacement

First, disconnect the transmission end and remove the nuts; then disconnect the inner cable from the pedal.

May have a loop that fits over the hook at the top of the pedal; pull the cable and remove it.

The cable may end with a fork, which is turned on the pedal by a cotter pin. The pin has a head at one end and a washer and cotter pin at the other. Straighten and pull out the cotter pin using pliers, then push out the cotter pin. When installing, use a new cotter pin.

If there is a ball at the end of the cable that fits through the keyhole shaped slot in the pedal, pull the cable and push it toward the large end of the keyhole to release the ball.

Remove all bolts that secure the outer shell to the bulkhead. Pay attention to the order in which the washers, spacers, and seals are installed so that they can be replaced correctly. Pull all cable through the engine compartment.

Some rear-engined cars, such as the VW Beetle, have the clutch, brake and accelerator pedals on a common shaft. To free the clutch cable for replacement, you may have to disturb the other two pedals and links.

To get to the end of the clutch cable, remove the left rear wheel that supports the vehicle on the axle mount. Adjustment is usually accomplished by turning the wing nut or the knob nut and lock nut on the end of the clutch.

Hold the cable by the handles so that it does not rotate along with the nut during adjustment. Turning clockwise reduces the free play of the pedal, which should be between 10 and 25 mm. Make sure the adjusting nut is seated correctly in the elliptical hole of the clutch lever.

VW Beetle cable replacement

When replacing the VW cable, adjust it on the clutch. Thread the threaded end through the hole in the lever and install the wing nut. During final adjustment, hold the cable by the handles to prevent it from turning.

Check all rubber grommets and seals along the cable route and replace any that are worn or damaged. Some may come with a new cable.

Take the old cable and other replacement parts to a parts store. Lay the old and new cables side by side and make sure they are the same length and have the same fittings.

If the old type has been replaced by an approved but slightly different one, make sure you have the adapters you need.

Find out if the new cable needs to be lubricated before installation. Most modern cables have grease-free, non-stick coatings.

If you do need to lubricate the cable, use your finger to push as much high-temperature grease as possible into the outer sheath at both ends and slide the cable back and forth to distribute the lubricant.

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