Early on after I purchased the Karmann Ghia, I repaired the inoperable rear deck lid release cable. I purchased a new cable and a new cable housing. The stock cable housing is made out of a plastic material and is designed to fit into the rear deck lid release mechanism.
Initially the release cable worked well but after time it was taking way more effort than it should to open the rear deck. I suspected the cable housing that pushes up against the rear deck lid release cable anchoring sleeve that is installed next to the rear jump seat was the problem. For some reason the cable housing was not rigid enough to hold its length when the cable was pulled. After doing a little web surfing I learned that some people were using bicycle brake and shifter cable housing in place of the plastic housing. This makes some sense, given the cables are designed to function in the elements and need to be strong enough not to change length during braking or gear changes. I stopped by a local bicycle repair shop and found what I wanted. The cable housing is made out of a rolled metal band that provides a rigid length but allows the housing to be flexible. The outside is wrapped in vinyl and there is also a vinyl inner tube that provides a smooth surface for the cable to move back and forth within the housing.
I had to install a collar on the end of the cable housing that feeds into the rear deck release anchoring sleeve. The steel inner housing provided a rigid surface to secure the collar with the set screw. This is important to “fix” the length of the cable housing, otherwise the cable housing will move deeper into the anchoring sleeve as the cable is pulled. I routed the new cable housing through the rubber grommet in the metal panel over the rear wheel well and then to the release mechanism. Once I had the cable housing in place it was a simple matter to feed the release cable and adjust the position of the release arm so lock mechanism would be in the correct resting position.
A quick test…with the rear deck lid closed and secure, a gentle pull of the release knob and the deck lid sprung open. I am guessing this will be a more satisfying fix.
