Clutch Cable Job Kit — Cut The Tunnel Once, Never Fight It Again

Replacing a clutch cable on an air-cooled VW is one of the most cursed jobs on the car, because the cable runs through a sealed tube inside the tunnel with no access. When the cable snaps, or the tube is packed with fifty years of rust and grease, you are fishing blind.

Once you're already committed to cutting the tunnel, the second opening costs about twenty extra minutes and saves you the whole job next time. And since the tunnel is open and the shift rod is sitting right there looking at you, the bushing goes in while you can actually see what you're doing.

Do it once. Bolt the covers on. Walk away.

What's Included

• Forward Flush Tunnel Cover Kit (CH27) — weld-in threaded frame, bolt-on flush cover, stainless button-head hardware. Gets you at the forward cable tube.
• Flush-Mount Center Tunnel Access Plate Kit (CH28) — weld-in flush plate at the center tunnel location. Gets you at the shift rod coupler and the middle of the cable run.
• Washburn's Snap-Lock Delrin Shift Bushing (CH01) — CNC-machined virgin Delrin®, cut on-size, snaps in without clips or safety wire.

Component price if bought separately: $210. Kit price: $175. That also beats buying the Full Tunnel Access Bundle plus the bushing separately.

Vehicle Fitment

• Beetle (Type 1): 1949–1979 Standard & Super (CH01 fits 1960–79)
• Karmann Ghia: 1956–1974
• Type 3: 1961–1973
• The Thing: 1973–1974
• Chassis: Swing-axle and IRS Type 1 pans; buggies and custom builds on a standard VW pan

Before You Start

• The tunnel is a structural member and it carries the fuel line, the clutch cable tube, handbrake cables and often wiring and brake lines. Know what is in there before a cutting wheel goes in.
• Disconnect the battery. On a Beetle it sits under the right side of the rear seat, close to where you'll be working.
• Have a fire extinguisher within arm's reach. You are welding on a car with a fuel line in it.
• Never use chlorinated brake cleaner anywhere near where you will weld.

Frequently Asked Questions

• Do I need both openings? Not strictly — either one alone makes cable service far easier. But if the pan is apart and the interior is out, doing both is the cheapest time you will ever spend on this job.
• Does this require welding? Yes. Both plates are weld-in. If you don't weld, look at the bolt-on CH29 instead and buy the bushing separately.
• Will the covers sit flush under carpet? Yes — both are flush designs that sit level with the tunnel floor.
• Do they come coated? No — bare laser-cut steel. Paint, powder coat or seam seal to match your build.

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The Washburn's Metal Signature Series · Bundles & Kits · Structural Chassis & Fabrication · No welder? Bolt-on version here

⚠️ WARNING (California Prop 65): This product can expose you to chemicals known to the State of California to cause cancer and reproductive harm. For more information go to www.P65Warnings.ca.gov.