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Campy Derraileur Cable Housing Failure Mode

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Campy Derraileur Cable Housing Failure Mode

Old 07-15-13, 01:41 PM
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tanguy frame
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Campy Derraileur Cable Housing Failure Mode

I'm running Campy Chorus 10 speed drivetrain and I notice periodically that the rear derailleur cable housing fails when the strands of wire that make up the housing, running papallel to the cable, slip past the ferrell and through the stop and pop out the other end and puncture my thumb. This effect softens the rigidity of the housing and causes sloppy shifting and small puncture wounds. This happens with and without ferrells.

In the old days, we had coiled wire housing and as long as the ends were properly trimmed, the ferrells would STOP the cables as intended. Now, with the Campy gear cable housing, the cable stop in the ergolever doesn't really stop the housing.

Has anybody else noticed this failure mode? What remedy worked?
Thanks,
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Old 07-15-13, 02:23 PM
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Are your ferrules genuine Campy or some off-brand? With Campy ferrules, the hole should be just slightly larger than the cable and the housing wires should not intrude. Substituting a brake cable ferrule could cause this problem, since the hole should be larger.

The 2009+ shifters don't use ferrules at the shifter and use smaller 4.1mm cable housing. There is a very small metal washer placed in the shifter housing that acts just like the end of a ferrule.

I've used Campy since 1995 and never had this problem.
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Old 07-15-13, 02:24 PM
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Modern shift cable housing is a parallel wire design- it doesn't compress the way spiral winding does when under tension. If the ferrules are letting the housing strands through, you need to do a better job finishing the ends of your housing and maybe think about higher quality ferrules. I have never had that happen.
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Old 07-15-13, 03:06 PM
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Agreed, good quality ferrrules plus care to keep the ends evenly cut should prevent any problems. Any end(s) longer than the rest will tend to spring the housing to one side and make it easier for one to push through the ferrule.
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Old 07-15-13, 03:36 PM
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The Campy cable kit didn't come with ferrules or washers that I can recall... My ferrules were Jagwire (gasp!).
I'll look for those tiny washers...

Thanks!
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Old 07-15-13, 04:24 PM
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Originally Posted by tanguy frame View Post
I'm running Campy Chorus 10 speed drivetrain and I notice periodically that the rear derailleur cable housing fails when the strands of wire that make up the housing, running papallel to the cable, slip past the ferrell and through the stop and pop out the other end and puncture my thumb. ....

Has anybody else noticed this failure mode? What remedy worked?
Thanks,
This is common, but doesn't have to happen. It's the result of using the wrong kind of ferrule.

Typical ferrules have conical bottoms, reflecting the point of the drill. This forces wires toward the center, which can pinch the inner, and later extrude through the hole.

Ferrules designed for index housing, have flat bottoms, or even reverse cone bottoms which force the strands out away from the hole. They also have thicker structural bottom to prevent collapse. These ferrules can be made in one piece out of brass, then nickle plated, but they cost more because of the extra step to shape the bottom. Or they can be made of plated brass or plastic with a shaped stop forced down to the bottom.

I've lost touch with what the various companies sell, so you have to check by pushing a spoke in along the wall and seeing if it deflects to the hole when it hits bottom.

Ferrules are the Rodney Dangerfields of bike parts -- they don't get no respect. But they're actually engineered parts that have to be right to do their job.
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Old 07-15-13, 05:21 PM
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Originally Posted by tanguy frame View Post
The Campy cable kit didn't come with ferrules or washers that I can recall... My ferrules were Jagwire (gasp!).
I'll look for those tiny washers...

Thanks!
Yes, it did. They come in a small plastic bag that's been inside the box on every single Campy cable kit i've seen in over 20 years. Oddly, only shift housing ferrules. You get to supply your own brake housing ferrules.
Cutting the housing cleaning and using quality ferrules are 2 things that will keep this from happening. The other thing is to replace your housing on a yearly basis if you ride regularly.
This is not a "failure mode", whomever is working on the bike isn't doing something correctly or using poor quality ferrules.
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