Anyone had this problem? Clutch cable 'top hat' grommit pulling through?

[supercharged spaniel]

On the clutch cable there is a rubber 'top hat' grommit that goes through the top of the box.  Now a few of these I've had have ended up getting stressed and ripping and pulling through the bracket because the edges of the cut out on the bracket cut into the rubber and therefore your biting point then becomes lower as it breaks down.  Not a huge issue I may add but I thought about putting a stainless steet washer on to prevent this but then thought this might eventually wear the aluminium bracket on the box.  Something I personally didn't want. I hope I have explained this correctly.

To solve this I used a milling machine to cut out a 5 mm thick Nylon washer and fitted that between the top hat and the bracket.  Problem solved so far.  I'm going to leave it be for a while and see how it stands up to the stresses of the clutch being depressed etc

If anyone else if having these problems I can make some up for literally the cost of postage. About 50p or something.  I may need to buy some new nylon as I don't have loads but if people are interested I'll sort it out.  I'm not interested in making money, I've simply found something that pissed me off and if someone else has the same issue then here is a possible (fingers crossed) solution.

Anyone who wants to make their own, the inner diameter of your washer needs to be Radius 8.5mm  and the outer should be Radius 17.5mm.

Dan

[dannyb.G40]

Dan i would be interested in this, i go through clutch cables about 1 every six months and it is always this that goes first. It feels horrible when it brakes down as it leaves "play" in the pedal

[Varley]

I have this problem too, in fact I pretty much include clutch cables as a regular consumable..

Can't exactly understand what you're replacing with what but count me in.

Good 'fix it' attutude by the way!

[supercharged spaniel]

Ooohh well it's nice to see am not the only one. Well I'll take some pics this week and machine a bunch this week. I'll let yous know how many I've made by the end of the week and post back. I've been checking mine all weekend and it still looks great so am happy to say it's a fix well done. To fit them you need to take the 2 nuts off the cable, pull the metal washer, rubber retainer and little plastic seat that sits on the arm.  Then pull off the corrogated rubber protector. Now slide the nylon washer and refit everything and retighten the clutch cable.