Cable housing plastic ferrules
 

Ok, I don't understand why Shimano ships plastic ferrules with their brake housing. I've now had them crumple twice on a brake install. I'm picking up some aluminum ones tomorrow. Is there any self-respecting mechanic that uses plastic ferrules?

I do, and I've never had one cause me any problems. What exactly are you doing when they crumple?

I think it may be related to it being a new frame, and the cable stops have too much friction - can't seat the ferrules properly prior to fully engaging the brake.

I've never seen plastic ferrules for brake housing so if Shimano is now providing them, that's new. They have always used plastic ferrules for their shift housing and they work well in this application since the load on shift housing is far less than on brake housing.

Any chance the stops are sized to not require ferrules?

That's what came with my brand new shifters.

I'm almost positive that is not the case, but I will spend 5min to confirm and report back.

^ Ferrules are supposed to be used.

The stress on plastic ferrules on brake cables is really not all that; if the ferrule is fully seated on the cable, it's all supported by the housing underneath it. In the past seven years, I've built up seven bikes for myself and family, from bare frames. Five of them have had plastic-ferruled brake cables, and I've never had a problem.

If the ferrules are not sliding into cable stops smoothly, don't force them; spread the stops slightly with a small screwdriver until they DO slip in smoothly. (Remember: slow and careful, ALWAYS, with bike assembly)

The thought of spreading the stops makes me anxious, to say the least. I'd rather grease up a metal ferrule, and let it work it's way in.

I always use brass ferrules for brake cable housings; plastic ones for shift cables only. As the OP has observed, they do fail. Why chance it?

Okay, do it your way. Good luck to you.

I've not yet seen plastic brake casing caps. Yes to gear casing, of course. As I think about the possibility I wonder if the need to manage the casing routing and end finishing will be of greater need. We've set up some Ultregra push button bikes and XTR recently and none were problematic.

But I will say that the big "S" does change things without all knowing, until a bike comes along... Andy.

lineinthewater, I've seen two styles of the plastic brake cable end caps, smooth and ribbed. The ribbed ones didn't fit and the smooth ones did fit as they are much the same size as the metal caps.

Brad

did you force the gear ferrules on brake housing?