Throttle Cable Rubing, How I fixed that dragg'n feeling Options

[ctc911ctc]

Teeners,

'74 2.0

The pedal assembly was rebuilt, painstakingly cleaned and then powder coated. greased to perfection and then installed.

New Clutch and throttle cable, rebuilt calipers on all 4 corners, brake lines, etc.

All worked great with the exception of the gas pedal. It just seemed to be grabbing when depressed. Ugh

Today I tackled this job, took a few hours - this is what I learned.

First I followed in the previous steps suggested here in 914W

1. Wrapped Around the clutch pedal? No, no throttle movement when depressing clutch and with a mirrored light was able to visually verify.
2. Guide crushed or bent. No
3, firewall to engine turns too tight? Verified long bends, within an acceptable range.

So,

I took the cable off of the throttle body and started to debug.
Seems that the factory that built this cable (German but not stamped as a Porsche part - did not cost a great deal as well) used a bundle of rigid wire as a guide. This guide is then either shrink wrapped or dipped in plastic for the coating.



I found that the cable when pulled across these wires managed to snag every few millimeters. Just enough to provide that dragging feeling.



I decided to push the plastic sleeve shown above down into the wire guide so that all of the guide wires surrounded the plastic sleeve. This removed the opportunity for the wire-against-sharp wire edge to connect thereby removing the snagging that was felt in the pedal. I added a few dabs of epoxy to bond the plastic sleeve to the surrounding wires (careful not to get any on the internal cable) and the results were slicker than snot on a glass door knob! Perfect throttle feel.

Oh, before I did this I also tried to file the wires hoping to remove the sharp edges. Wasted an hour there.