Aero levers brake cable replacement
 

Hi all, I'm thinking of replacing the brake cables on my late 80s road bike equipped with aero levers. I'm wondering if it is possible to route the new cable in without removing the bar tape, cable housing and/or the brake levers themselves? I've searched the net and this forum but couldn't find anything that addresses my question. Any input is appreciated! Thanks.

OMG never ever blog before coffee!! *blushing*

I totally misread this. I though he was replacing the levers OMG I feel soo blonde.

Yes. Sometimes you can get lucky and snake the new cable through the housing. It all depends on how much tolerance there is where the cable exits the lever body.

Usually it's easier just to retape, time-wise.

I've had the best luck as follows:

1. Remove old cable.
2. Unscrew the lever from the handlebar band clamp. Usually this is by means of an allen bolt.
3. Thread the new cable through the lever, then through the cable housing. Don't attach to the brake caliper yet.
4. Carefully re-attach the lever.
5. Attach cable to caliper, adjust, clip, finish cable end.

Yes, in fact I've never had any problems doing this. Use jb's tips if required, but I usually don't have to.


[Edit: OP clarified]

Let me put it this way: Good luck.

-Kurt

Thanks all for your response. I'll give it a try and hope for the best.

Sorry for the confusion guys. Now that I read my original sentence again it really was badly worded. Suggestion taken and post edited.

That looks like just as much, if not more, effort than just rewrapping the bars.

No it doesn't.

now that I am awake and recovered from my embarassment, I normally had good luck just putting new cables in. most newer levers should't give you much trouble. the oddball early DiaCompe or Modolo may be tricky.

just being nosey here why change them?

I recently replaced some brake cables as you are describing without any difficulty. I recommend applying a bit of lube to the new brake cable before you insert it into the housing. And good lighting helps, too, as you should be able to see the hole in the housing through the brake lever.

I've replaced the cable without any problems on my '90 105.

id rather repack my bottom bracket than retape my bars.

I'd rather do either of those two than build a wheel.

-Kurt

I can retape my bars, build a wheel and repack a BB faster than I can replace a flat clincher.

I don't aim well enough to route the new cable right into the housing, through the attached lever body.

However....

I simply roll the hood back from the bar, unbolt the lever body, and pull it off. I route the cable through the body, then into the cable housing, and on to the end of the rainbow to the caliper. Then I pull it and reattach the lever body, roll back the hood, and then tighten and adjust the cable.

5 minutes.

It's actually not a bad idea to unwrap your bars and install the cables that way. Doesn't take too long, and as long as your tape doesn't have adhesive on the back it's effortless. Besides, you can get it nice and tight around the bars again and have good strong brakes and a nicer aesthetic to your bars which likely had sagging bar tape you weren't aware of.
-Gene-

Thanks again everyone for more input. Last night I did it successfully without removing the tape or lever. With a flash light, I was able to see the 'hole' into which the cables go. It was uneventful with the back cable . The front cable however was already cut short (in hindsight dumb move) and there was one spot in the housing where I had to use a bit of force to push the cable through. It came out with two strands slightly 'pushed back' at the end that they bulged out a bit in the braiding pattern for about 3 inches back. Good thing steel strands hold their shape well and I was actually able to lift and unwind the strands a few inches back and wind them on again so they fall back in nice and smooth.

The old cables were probably as old as the bike and although they were not rusted, I figured they were cheap and simple enough to be replaced as part of my rehab work. The housings and Benotto-like bar tape are still clean and in perfect shape so I want to get at least another season out of them with my light riding.

The thing is, that unless there was a mishap, chances are that when you need new cables, you need new bar tape (and tires and some other things.) I routinely do maintainance on my bikes on certain mileage intervals and change everything at once. I find it more simple this way rather than doing it piece by piece (and the bike gets off circulation only for part of a single day)

Point taken E, and it totally makes sense. If/when I'm more seasoned in bike restoration I'd definitely do 'the whole package' all at once. The original cables were okay and I could've left them. I just felt like doing a more complete job, within my DIY ability and budget, in my restoration task.

Bianchigirl beat me to it for the caveat regarding some Dia Compe aero levers. These used a hemispherical ferrule for a cable housing stop in the back of the lever. If you're not precise in pushing the cable end through the hole, you can dislodge the ferrule and it drops into the lever. And thus unwrapping the tape and body removal follows. @$#$^@#$.

Congrats on your success. Next time, if you're pushing the cable through unlined housing (which sounds like what happened), dab the end with a little crazy glue. Keeps the strands tight while negotiating tight bends.