DOS

Hi

A buddy of mine asked me to replace his rear derailleur cable. Come to find out, it needs replacing because cable broke in the shifter. Near as I can tell, my buddy removed the broken part of the cable from the shifter without leaving any bit behind. However, when I went to install the new cable, I immediately noticed that the shifter was not shifting correctly. It clicks only three times so I cant get the mechanism into highest position where cable can be installed. The problem seems to be same or similar as the one described here: https://www.bikeforums.net/showthread...jammed+ultegra

But, like I said, I am not sure there is any cable still stuck in the shifter or whether the current jam was caused by or was the cause of the broken cable.

I disassembled the shifter enough to be able to see the ratchet mechanism moving as I shift. Basically, on the third click of the inner lever, the toothed gear wheel moves a little and the dohicky that is lifted by the lever and is supposed click over the top of tooth to settle in between two teeth gets hung up and doesn't drop back down. Since its not my shifter, I am hesitant to disassemble any further or stick any tool in there to try and force the issue. But before I surrender and tell my buddy to get a pro or a new shifter, I thought I'd ask for any ideas.

Edited to add: I also shined a light down into the shifter. I can see along the groove the cable is supposed track pretty far into the shifter and I see no evidence that any bit of cable is still in there. There just doesn't seem to be enough room down in there for a broken cable head to be jamming things up, but I suppose its possible.

mechBgon

I'd start by just asking him whether he removed the head of the cable or not. He ought to remember extracting it if he did. It's also possible that while the head has been removed, bits of frayed cable strands remain.

Next, gently pull the brake lever blade outboard and now try the upshift paddle again. If the brake lever blade isn't returning to its neutral position, it prevents the upshift paddle from operating, and while it ought to work without help from cable tension, you know what they say about theory versus reality

Oh yes, they can get so far in they're out of sight.

So where's that leave you? Any good?

DOS

I had just sent him an email asking the very question about the cable end when I noticed that with shifter lever turned inward and brake lever depressed, I could shine a light down into the mechanism from the outboard side of the lever and could see further into the mecahnism than I had before. Sure enough, I can just make out some strands of cable. So next question is, how the hell do I get it our of there?

mechBgon

Oh fun. If you have any stiff wire, bend a tiny hook in the end of it and try fishing out the cable head (which is probably down there with those strands protruding from it).

DOS

VICTORY.

Working from outboard side with brake lever depressed and flashlight in my mouth, I was able to get hold of a strand of cable with tweezers from my swiss army knife and tug. That freed up shifter enough to click 5 times instead of three, which revealed enough additional cable to get hold of with needle nose. Another tug on the cable popped the head back in place, and I was able to click it all the way around to neutral and pop the cable end out of there. That was fun.

mechBgon

Nice It's not a bad idea to put a new cable in every 3000 miles or so, as a preventive measure.

reptilezs

our service writer/write up guy checks all the cables on bikes with shimano non hidden cable shifters that come in for fraying. it always feels good to fish a broken cable head out.

davidad

Don't you just love the new and improved stuff. I have a friend who has a 10 sp shimano and when he broke a cable we had a hell of a time getting the thing out.