Date:         Tue, 18 Sep 2007 10:19:19 -0400
Reply-To:     Daniel O Stevens <dosteven@SYR.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Daniel O Stevens <dosteven@SYR.EDU>
Subject:      Re: throttle cable replacement
Content-Type: text/plain; charset="us-ascii"

I JUST changed, actually UPGRADED the throttle cable on the new ot me 80
aircooled.

But the front end of the stock cable won't fit out the back end. 

You need to remove and install it @ the front.
----------------------------------------------------------------

Now for my Upgrade, ever since I've had buggies&bajas I've preferred a
good 3/32" garage/aviation cable instead of the miniscule stock cable. 

You goto your local big box store, and in the hardware isle ask for
15~17ft of 3/32" garage door cable. 
It's approx $.25/ft not a big deal breaker. 

You Solder the end for the throttle arm be mindful of a NEAT solder, a
big glob won't fit in the tube.
Then with some latex gloves I use some Marine bearing grease glob in one
hand and pass the cable thru the grease into the housing.. Till my
assistant says it's poking out..  When you get close to where you think
the cable will end (you can pre measure by laying out under van) secure
it to the throttle.
Secure it to the pedal pivot locking barrel bolt.

And once you are happy you have the throttle all the way closed, and
pedal all the way up.. 
Maybe leave pedal 1/4" slack for feel 
You can cut the cable but leave it 'short' as too much sticking out will
bind in the box.

I cut a slit in my box so I can slide it on AFTER I put the throttle
on.. And none of mine have ever come with the rubber boot intact. I rely
on the ample Marine grease and semi-annual maintenance to inspect and
lube the cable from corrosion and binding/chaffing  
I like to drop and inspect my spare and hoses each season.  I also store
my 20ft extraction nylon strap in a ziploc bag (big storage size) inside
the upturned spares cavity)..

That's my tech for the day..

Dan Stevens
VW club of Central NY www.vwccny.com
Empire vw camping club 
http://autos.groups.yahoo.com/group/Emp_VW_Camping_Club/




Date:    Mon, 17 Sep 2007 20:09:50 -0600
From:    Don Spence <dkspence@TELUS.NET>
Subject: ?

I guess I should have been more explicit with my question. From which
end do you feed the cable in. Foot-well or engine compartment?
83.5 1.9 wbx manual trans.

  TIA
Don