How to Measure Your Control Cable for a Perfect Replacement

Ordering the wrong length or fitting is the most common reason a replacement control cable doesn't work the first time. A cable that's too short won't reach, one that's too long can bind or kink, and mismatched end fittings won't connect to your throttle, shifter, or brake lever at all. The good news is that measuring a control cable correctly isn't complicated once you know what to look for. Here's how to do it right.

Start With the Old Cable, Not Guesswork

If you have the old cable in hand, even if it's damaged or worn out, that's your best reference. Lay it out flat on a clean, straight surface, without stretching or compressing it, and measure end to end. If the housing is bent or coiled from years of installation, try to let it relax into its natural shape before measuring, or measure it while it's still mounted in the vehicle if that's easier.

If you don't have the old cable, or it's missing entirely, you'll need to measure the routing path directly.

Measuring the Overall Length

• Measure the full routing path, not a straight line. Control cables rarely run in a straight line from one end to the other. Follow the actual path the cable will take, around brackets, through the firewall, along the frame, including any bends, and measure that full distance rather than just the point-to-point distance between mounting locations. A cable measured in a straight line will almost always come up short once it's routed.
• Measure between the mounting points, not the cable ends. What matters is the distance between where each end fitting actually attaches, not the overall length of the housing including the fittings themselves. Manufacturers typically specify cable length as the housing length between mounting brackets, so this is the number to give us when ordering.
• Account for any adjustment range. If your application has an adjustable clevis or threaded end, note how much adjustment range you have on each end. This gives a little flexibility if your measurement is off by a small amount, and it's useful information when we're building your cable.

Measuring End Fittings

Getting the length right only solves half the problem. The end fittings need to match your throttle body, carburetor, shifter, or parking brake lever, or the cable won't connect at all.

• Identify the fitting type on each end. Common types include a threaded stud, a clevis pin, a barrel/nipple end, or a specific bracket mount. Take a clear photo of each end if you're not sure how to describe it, that's often the fastest way for us to confirm what you have.
• Note the thread size, if applicable. Threaded ends are typically specified by diameter and thread pitch (for example, 10-32 or 1/4-28). If you have calipers, measuring the outer diameter of the threads gets you most of the way to identifying the size.
• Check both ends separately. It's common for a control cable to have a different fitting on each end, one side threaded, the other a clevis, for example. Measure and describe each end individually rather than assuming they match.

Measuring the Housing and Core

• Housing diameter matters for cable stops and clamps. If your cable routes through a bracket, grommet, or firewall opening, the outer diameter of the housing needs to match the hardware holding it in place. A cable stop or clamp sized for the wrong housing diameter won't hold the cable securely.
• Core type affects flexibility and duty cycle. A stranded, flexible core suits tighter routing with more bends, while a solid or heavier-duty core suits throttle cables and applications with fewer bends but higher force. If you're not sure which your application needs, let us know what you're installing it on, and we can recommend the right build.

When in Doubt, Send Us Your Cable

Measuring a control cable accurately from scratch, especially one with a bent housing or an unusual fitting, can be tricky to get exactly right. If you have the old cable, even a broken or worn one, sending it to us is the most reliable way to guarantee a correct match. We build custom control cables to your exact length, fittings, and housing, so there's no guessing on your end and no adapting a generic part to fit.

Frequently Asked Questions

What's the best way to measure a control cable if the old one is broken? 

Broken cables can usually still be measured. Lay out both pieces together in their original positions if possible, or measure each section and add them together. If the break makes accurate measurement difficult, sending us the pieces is often more reliable than a manual measurement.

Should I measure from the tip of the fitting or the mounting point? 

Measure between the actual mounting points, where each end attaches to your equipment, not the overall length including the fittings. This matches how cable length is specified when ordering.

What if my cable has an adjustable end? 

Note the current adjustment position and how much range is available. This gives us useful context and a little built-in tolerance if your measurement is slightly off.

Can you build a custom cable if I only have photos and measurements, not the original cable? 

Yes. Clear photos of each end fitting along with accurate length and housing diameter measurements are usually enough for us to build a correct match.

Do I need to know the exact thread size before ordering?

 It helps, but it's not required. If you're not sure, describe or photograph the fitting, and we can help identify the correct thread size and end type for your application.