Date: Thu, 16 May 2013 10:43:07 -0400
Reply-To: Jeff Lincoln <magikvw@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Jeff Lincoln <magikvw@GMAIL.COM>
Subject: 1.9 Manual Trans Accelerator Cable Replacement
Content-Type: text/plain; charset=windows-1252
Per a request from a list member here is my write up on replacing the
Accelerator Cable for a 1.9 Manual Trans (this could be the same for a 2.1
as well but I am not sure).
The job is a lot simpler than my written process may make it seem to be. It
should take maybe 30 min. tops - probably quicker if you're in a hurry :)
The cable is attached to the van in 4 places:
1. By a barrel clamp at the throttle assembly. The clamp on my van was
secured with a standard .05 allen type set screw. Yours may be different.
2. By a clip on a bracket on the top right of the transmission (right
is the passenger side of the van) – it’s just beyond the firewall but not
hard to get to.
3. By a plastic mount on the cable attached to the frame near center
and at about the ½ way point of the van. This is a 10mm bolt and nut
4. In the front to the pedal mechanism. The end of the cable slides
into a hole in that mechanism and is held in place by an 8mm bolt. (this is
located under a plastic dust cover)
Here is the process I took:
1. Remove the engine end of the old Cable
a. Make note of where the Barrel clamp at the throttle end is on the
old cable end. Measure if necessary. We want to place it in close to the
same position on the new cable
b. Remove the barrel clamp from the old cable and remove the cable end
from the throttle assembly.
c. Remove the retaining clip that secures the cable to the bracket on
the Trans. This is a slide type metal clip that clips onto a round plastic
fitting on the cable. There is a slot so you can get a blade end screw
driver in there and just pop it off.
d. Fish the old cable through the hole in the bracket and down under
the van.
2. Attach the new cable at the engine end of the van.
a. Simply do the reverse of the steps above and secure the new cable
to the engine end of the van.
3. Remove the plastic mount that is attached to the frame.
a. Climb under the van and find that plastic mount (this plastic part
is part of the cable assembly itself)
b. It is fastened to the frame with a 10mm bolt/nut. If yours is like
mine was, it will be very rusted. I was able to get mine apart fairly
easily using PB Blaster and a little patience. I replaced it with a new
bolt and nut.
c. Once removed attach the plastic mount of the new cable to the frame
in the same spot.
At this point you have the new cable in place from the back of the van to
the middle and the old cable in place from the middle to the front. You
will notice that the old cable going forward is inserted into a plastic
tube/sleeve (this is not to be confused with the smaller diameter plastic
tube that is part of your new cable). This tube/sleeve stays in place DO
NOT remove it. If the old cable isn’t already broken (mine was) now is a
good time to cut it. You want to cut it so that all that is left from the
middle of the van to the front is cable and you are rid of the plastic
middle mount and all the other excess parts that were toward the back. The
idea is to be sure the cable is in a state where you can pull it through
that tube/sleeve from the front.
4. Detach the old cable from the front pedal assembly and pull it
through the tube/sleeve
a. Go to the front of the van and drop your spare tire carrier –
remove the spare tire so you have more room.
b. Stick your head under the front left (driver’s) side of the van and
look up to where your accelerator pedal is. You will see a rectangular
plastic box and will notice the old cable goes into it. It’s just a
dust/dirt cover. If yours is like mine was several of the points where this
box screws to the underside are broken and it isn’t really secured very
well. Either way remove the screws that mount that plastic box to the
underside.
c. You can now slide that back out of your way and see where the cable
is attached to the pedal assembly.
d. Loosen the 8mm bolt holding the cable end in place and remove the
cable from the assembly
e. Now you can slide the dust cover box off of the front end of the
old cable
f. Now pull the old cable forward and out of the tube/sleeve
5. Now go back to the middle of the van and slide the new cable into
that sleeve until it comes out the front end. Because the cable has that
small plastic covering the cable should slide right through. No need to
fish it through or attach it to the old cable to pull it through. It will
go easily on its own.
6. Attach the new cable to the pedal assembly
a. Insert the new cable into the hole on the dust cover.
b. Slide the end into the pedal assembly and tighten the 8mm retaining
bolt
c. Put the dust cover back in place and put the screws back in.
There you’re done!!!!
If the cable needs any adjustment later (mine did not) you can adjust it to
where you need it at the throttle assembly by moving that barrel clamp
forward or back on the end of the cable.
Even though the new cable was…new, I did give it a little spray of WD-40
where it goes into the small plastic covering at each end before I
installed it. I also took the opportunity to use a little grease on the
pedal assembly while I had the dust cover off.
As for the dust cover mine was pretty well useless with 3 of the 4 mounting
points broken. I’ll find another one – but in the mean time I used RTV
around the edge of the cover where it meets the underside of the van. I
kind of glued it in place with that until I can replace it with one in
better shape.
Thanks,
Jeff
'85 GL (Gertie)
'78 Bus (Melissa) Patty's Bus
