gear cable removal dura ace 7801 STI right hand lever?

sevenofeleven
sevenofeleven Posts: 74
edited February 2008 in Workshop
I am trying to remove my gear cable from my STI right hand lever but cannot seem to get the cable end out of the hole on the outside of the lever i can see how it is held in place but cannot pop it out! any tips before i have too go to LBS cap in hand! the Shimano/ Park tools website is not much help . Sheldon Brown RIP

Comments

  • redvee
    redvee Posts: 11,922
    If they are anything like the 105 STIs I had on my bike, there is a little rubber grommet on the outside of the lever. Pop this off but don't lose it, keeps the good stuff in the lever and then jiggle/push the cable out of the lever.
    I've added a signature to prove it is still possible.
  • sevenofeleven
    sevenofeleven Posts: 74
    I dont seem to have the gromet as the housing looks all 1 piece! thanks for replying 1 gear is enough! i should just stick to riding my fixed wheel less hassle all round!
  • alfablue
    alfablue Posts: 8,497
    When you have it in the right gear the cable run will be straight and it should push out easily. Try going through the gears till it goes free.
  • sevenofeleven
    sevenofeleven Posts: 74
    Tried all the gears got lovely straight view I can see the jaws holding the end of the cable which moves freely but i cant pop it sideways to get it out even with very slim screwdriver trying to pop it sideways
  • alfablue
    alfablue Posts: 8,497
    Are you depressing the brake lever?

    See the tech doc here
  • sevenofeleven
    sevenofeleven Posts: 74
    Yep! and have already looked at tech doc before i started! i have noticed that the diameter of the cable is larger (like a brake cable) than my new cable which leads me to believe that the wrong cable might have been used originally with a bigger cable end hence stuck cable!
  • alfablue
    alfablue Posts: 8,497
    sevenofeleven wrote:
    Yep! and have already looked at tech doc before i started! i have noticed that the diameter of the cable is larger (like a brake cable) than my new cable which leads me to believe that the wrong cable might have been used originally with a bigger cable end hence stuck cable!
    Oh bugger! though the nipple on a brake cable would be too big I think - Oh, see "like" a brake cable. Its all pretty strange.
  • sevenofeleven
    sevenofeleven Posts: 74
    looks like a trip to LBS! as i'm not brave or stupid enough to take the STI to bits! Thanks for yor advice Alfa!
  • alfablue
    alfablue Posts: 8,497
    I once dismantled my shifter, I regretted it!!!

    Sorry I couldn't offer much help!
  • synchronicity
    synchronicity Posts: 1,415
    This is just one reason why I prefer campagnolo! :lol:
    vertebr.ae | precision braking & shifting
  • Dales1
    Dales1 Posts: 46
    On the question of cable size, my 2007 Dura Ace shifters have 1.2mm diameter inner cables, as per the technical document mentioned above.

    The chain must be on the very smallest rear sprocket. Then, as alfablue says, with the brake lever depressed - the cable should simply push straight through the nipple holder.

    Have you disconnected the cable everywhere else on its run, so you can slide the cable outer back to get a good grasp of the inner cable. Push the inner cable through, perhaps giving it a little twist clockwise and anticlockwise as you do so.
  • sevenofeleven
    sevenofeleven Posts: 74
    the cable in the sti measures 1.56mm according to my calipers the new cable is just 1.2mm just like yours! the cable is completely disconnected too! still no joy!
  • redvee
    redvee Posts: 11,922
    If you can get access to the nipple then it seems to be a pair of needle nose/radio pliers might be your saving grace.
    I've added a signature to prove it is still possible.
  • sevenofeleven
    sevenofeleven Posts: 74
    tried with very fine screwdriver!inserting inside and shifting sideways! no luck!
  • redvee
    redvee Posts: 11,922
    Tried a big hammer? :x
    I've added a signature to prove it is still possible.
  • sevenofeleven
    sevenofeleven Posts: 74
    Its 07.30 in the morning here so i'm just going nipping out on my other bike for a quick 2hr ride then will take it to LBS!
  • sevenofeleven
    sevenofeleven Posts: 74
    thought bout the hammer but couldnt get the wifes blood off of it!
  • Dales1
    Dales1 Posts: 46
    You're right - disassembling the STIs is a recipe for a real puzzle on reassembly.

    Also, you're not going to get much purchase on the well-stuck cable, simply by shifting sideways with the small screwdriver on the nipple.

    You could try 'carefully' tapping the end of the small screwdriver (placed on the cable end of the nipple, and as parallel to the cable as can be) to see if that will drive the nipple out. (You'll need three hands, one to keep the lever pressed in and sideways, one to hold the screwdriver, and one for the tapping implement!).

    Or, you could try using the stiffness of the 1.6mm cable to push the nipple out. Grasp the cable with the mole grips, fairly near the STI assembly, with the mole grips pointing along the length of the cable. Now push forwards without letting the cable bend at all (and with the lever 'not' pressed sideways this time, so as to keep the cable run flat).
  • sevenofeleven
    sevenofeleven Posts: 74
    Its in the LBS the guys seemed pretty confident about getting it out with taking it apart even when i explained the cable diameter issue! Apparently some "joker" did the same thing when STI's first came out and they managed to sort it!
  • sevenofeleven
    sevenofeleven Posts: 74
    Sorted by LBS! Bit of black magic got it out! thanks for all your replies!
  • alfablue
    alfablue Posts: 8,497
    Phew! I'm pleased to hear it!

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