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What a coincidence, I just did my right-hand side last weekend (did the other 2 years ago). But my cable was OK, so I can't help you there.

It is actually frayed (missing/worn strands) or have the strands just separated?

 

I read here in either the TR/Boxer forum or the 3X8 forum that someone had the same issue and replaced with wire rope from Home Depot/Lowe's. The biggest issue would be securing the end. The factory termination is a swedged-on crescent block. Don't think you would have much luck finding the same, but they do have crimp-sleeves that would essentially do the same thing and fit in the recess on the gear. Only thing I'd be nervous about is crimping the swedge; I have a purpose-made crimper that compresses the sleeves from my aircraft fabrication days, lacking that tool you could try "compressing" with a hammer Before you go that route PM me and I'll loan you my crimper.

The wire rope at Home Depot has an OD of 1/16" or 1.65mm, I think that is very close to the factory wire rope size. Should be just a matter of cutting off the terminations of the original ends, pulling out the wire, measuring and reinserting/crimping. Measurement does not have to be exact as the spring tensioner takes out a lot of play.

Hope it works out, you might try a search here to find the thread and PM the guy that had the same issue.

 

Jeff, to get to the other end of the wire you need to take the blue domed section off. To do that you need to compress it a little to be able to take off a small very fine circlip that holds it together. I used a section of pipe and cutout a section large enough to work through to pry off the circlip. Once you get it off it is simply a matter to make the new cable the same length as the old. I used a standard crimper with stainless swages and once crimped, I simply groung off enough of the swage to allow everything to sit back together. I will try to find some photos.

 

Thanks, and great pictures too!

 

For future search:

Was at my hardware store today for something else and picked up some 1/16" cable stops "just in case". My store carries the Midwest Fastener line of specialty hardware and these are their PN 6483002, $.40 ea. I don't have the correct crimper for these but did an adequate job--with some cleanup this would be fine.
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