Sliding Electric Door Cable Repair

BethL · Feb 12, 2018

The cable on our electric door of our 2009 California recently snapped. Purchased a replacement kit from eBay, and all is good apart from the fact we are unable to crimp the ferrule on the end of the cable securely enough to withstand more than a couple of openings before it pops off.

Has anyone had a similar issue and how did you resolve it? We don’t fancy paying VW the full cost they are quoting.

Any suggestions will be much appreciated

ArunAlec · Feb 12, 2018

Have a look at the video, about 40minutes in...

Another option, try a cycle shop, they should be used to crimping cable ends.

BethL · Feb 12, 2018

Thanks, looks like we are doing it correctly but can’t secure the ends on we’ll enough . We’ve tried an industrial crimper with little success too. Thanks for the video

owen_h · Feb 12, 2018

Any yacht riggers near to you? Think Ratsey are Pembrokeshire. They would be used to swaging wire.

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BethL · Feb 12, 2018

Thanks, may be worth considering

owen_h · Feb 12, 2018

Or maybe something like this that uses grub screws
http://wireropeshop.co.uk/wire-store/index.php?main_page=product_info&products_id=1248
That site also has swageless fittings if there is room.
http://wireropeshop.co.uk/wire-store/index.php?main_page=index&cPath=1_277_73

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BethL · Feb 13, 2018

Thanks, that may well be worth trying

kurienp · Feb 13, 2018

Grub screws is the way to go.

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BethL · Feb 13, 2018

Thanks, that may well be worth trying too

ArunAlec · Feb 14, 2018

If you are going to try the grub screw solution, which sounds worth a go. You might be able to modify a electrical connector - the "chocolate" block type. If you cut away the insulation the brass connector with its two grub screws might work. Assuming you got one the right size the only problem I can see is the brass being too soft to allow you to tighten without stripping the thread.

BethL · Feb 14, 2018

ArunAlec said:
If you are going to try the grub screw solution, which sounds worth a go. You might be able to modify a electrical connector - the "chocolate" block type. If you cut away the insulation the brass connector with its two grub screws might work. Assuming you got one the right size the only problem I can see is the brass being too soft to allow you to tighten without stripping the thread.

Thanks, we’ve got a few different options to try now, fingers crossed one of them works!

WelshGas · Feb 15, 2018

BethL said:
Thanks, we’ve got a few different options to try now, fingers crossed one of them works!

These might do the job.

http://wireropeshop.co.uk/wire-store/index.php?main_page=index&cPath=1_277_285

BethL · Feb 17, 2018

WelshGas said:
These might do the job.

http://wireropeshop.co.uk/wire-store/index.php?main_page=index&cPath=1_277_285

Thanks, another option

they-setter · Oct 27, 2018

which one did you go with ?

KGCali · Jun 3, 2021

This Russian guy uses a small hydraulic crimper that you can buy on Amazon for around £25. Take a look at his video at 9min45sec

KGCali · Jun 15, 2021

Just about to go camping last week and my electric sliding door cable snapped, typical!
After ordering the parts I managed to fix mine in an afternoon by following this video closely

There were a few difference, my 2010 California has small retaining clips to hold the wire ends into the door guide roller which prevents them coming out, the spring was on the outside not inside and I used a loop of thin nylon string to pull on the spring to pretension it. I also found it difficult refitting the panel with black clips like the original and so purchased some white ones that made it really easy, links below. I only had very slight noise as the cables and reels rewound initially but all quiet after about 10 opening and closing of the sliding door. The most important part is getting the pretension correct, I cut my cables 15mm shorter than the marked end position on each reel, see above video. I'd read various comments about issues crimping the ferrules so I purchased an hydraulic crimper that made it easy. Complete repair cost £12 plus £26 for the crimper so slightly cheaper than the VW quotes of £561.80+Vat to supply and fit

I found a few more videos online that do it slightly differently so thought I'd share as different methods of preloading, hope you find them useful ...
Spring on outside and hydraulic crimper (Amazon £25)...

Spring on inside ...