Pedal to the carpet...

[Dominic]

Two months ago, my tzd became agonizingly slow and amazingly economical - obviously a fuelling issue. All vacuum pipes OK, pump diaphram OK, turbo OK, - eventually realised the throttle cable had become so baggy, with pedal to the metal, the throttle was about 30% open! Curiouser and curiouser, the reason the cable had become baggy, is that the pedal, which is off-set mounted is bending the pedal box bracket. The accelerator pedal migrates further over to the right to a point where it doesn't actuate the cable properly. Its easy enough to bend the assembly back, but one day its going to break as its obviously made of cheese.
Is this a known issue, or has something fallen off that I haven't noticed? Any ideas on a fix?

[Vanny]

Very common issue, the angle on the pedal box fractures. You can weld the box up, or bolt a piece of angle in, or find another box. But do it quickly, it sounds like you'll soon loose the accelerator (which is a PITA when your 20 miles from home).

[mat_fenwick]

It's a common problem - I welded mine up earlier this year as although it had not yet bent, there was the start of a hairline crack. It was a fun job!

EDIT - Vanny beat me to it!

[themildbunch]

Before the premature demise of the engine on our TD - the pedal had been doing this for a while - got good at pressing with a 'twist' action.

Getting it out should be easy but it's the clutch cable connection and reconnection that's nasty especially on the TD where there's very little access from the engine side - Welded mine carefully in situ but this only lasted a few weeks - I'd try the bolting some angle iron down there or give yourself some time to take it all out go prepared with a spare clutch cable just in case...

[Vanny]

Welded mine carefully in situ but this only lasted a few weeks

I tried this too (though less of the carefully and more of the setting-fire-to-the-carpet method), and also found it didn't last long, and ultimately changed the box for a far fresher alternative.

[Mothman]

Damned glad i have a spare pedal box. Malcolm thought the TZds looked ok though.

Andy

[citronut]

i always weld two lengths of stud similar to Mats brace, also weld the crack back together (no not the one in the T Shirt thread )

regards malcolm

[Vanny]

Is it worth drilling above the crack first to stop it propagating?

[Mothman]

Is it worth drilling above the crack first to stop it propagating?

Probably a damned good idea this and filling the hold with weld although ime no expert on such issues.

andy

[mat_fenwick]

I don't think it'll make a difference if you're welding with good penetration, since you'll be making the whole area molten anyway. If you're bolting or brazing it it then it's a good idea!

[citronut]

no need to drill and weld as all the pedal box's i have repaired have not failed again,

the main thing is to weld the brace in this stop's sideways moment of the right angled section the pedal id bolted to

regards malcolm