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Broken throttle cable.. Topic is solved

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ACarmona
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Year and Model: 1996 850 R
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Post by ACarmona »

5 Days ago, 10/4/16:
Getting off of work and leaving the parking lot. Step on the gas as I finish my turn onto the side street and...thunk!....thunk..thunk...no response from the throttle. The pedal is totally floppy so I pulled over and popped my hood, inspected the cable at the throttle body and it seemed intact on that side, so I pulled on it a little and it just came right out from the outer sleeve. The cable was completely frayed at one end and had detatched from the ball and clip at the pedal. I decided I couldn't exactly idle my car home, although it was relatively close, so I reversed back into the parking lot of my work and parked it there. Thankfully, my roommate and I work together, we got off at the same time, and for some reason his girlfriend wanted to also show up just to give him a ride instead of letting me literally while this happened. Also, that must have been the most unlucky and lucky day that I've had yet because that morning I had received a shipment confirmation from IPD that I have been waiting to ship for almost 2 weeks now because of some back ordered items, and a brand new throttle cable along with some tune up parts was in that order! I knew I wanted and needed to replace it, but little did I know it would give up that soon! :x
Fast forward to today and thankfully again my package came yesterday while I was at work, so I head over to my work on my day off and replaced the throttle cable there in the parking lot. I got a lot of head nods and odd compliments out in public it was kinda fun, and was done in an hour after really struggling to get the kickdown switch assembly to come out of the hole in the firewall/body, as I did not want to cut up the inside foam to get to the other side like Robert did in his Video I ended up breaking the 3 tabs off the sides and pulled half of it off then pried with a screwdriver until I found the clips and pulled it out with some force. No damage to the actual hole was done, and I got the new one clipped in, cable attached, and adjusted smoothly.
I am so impressed by the responsiveness of my R now, and it really does feel like a whole new animal! I now have to contain myself at stoplights, while still not lugging the amazing-sounding I5. 8)
At home finally, just to be dismantled again partly to install new Denso Iridium Power Spark plugs, IPD plug and coil wires (yes, I did use dielectric grease to make life easier next time), and a Bosch Dist. cap and rotor. Definitely idles and delivers power a little smoother, but won't get any faster startup until I upgrade to the MSD ignition coil. I did order a CBV upgrade but after looking down there, Ill have to prepare myself to replace that in-car. Will do next time :D.
The Old Cable
IMG_20161009_172200.jpg
New Plug Wires and Throttle Cable
IMG_20161009_172417.jpg
It has been an eventful weekend, and am thankful I wasn't far away from home or merging onto a highway/freeway when this happened. My car also stayed safe in that parking lot over a few days, to which I thank the universe.
My advice to anyone: If you have any sort of sticking or heaviness in your throttle cable, please don't take the risk of putting it off and replace it as soon as you can! Just inspecting your pedal and the condition of the cable and connection can lead to ease of mind, and you will be able to adjust it properly if it already isn't.
Next on the list of things is the PCV upgrade, which was pushed back because the 5/8" brass elbows were just too small to fit snugly in the 5/8" hose so I ended up using 3/4" brass 90 degree elbows which fit tightly, so now I just need a drill and a 5/8" drill bit for the PTC. Then the new CBV diaphragm and blue spring will be the last upgrade I'll need/want to do to the engine before I move on to the Interior and Body, unless I can get away with adding FCP's upgraded aluminum intake J-pipe on top of the Stage 3 tune, 3" angled flange and DP, exhaust, and the bigger manifold and Throttle body, then I definitely will cause its stunning and am fed up with the black plastic corrugated tube after my MAF and short ram intake.
Thanks for taking your time for reading and responding if you do! I look forward to any input from anyone!
My 1st Car turned first project:
1996 854R; 199k miles, 3" Angled Flange and DP to 2.5" Turboback exhaust, IPD Stage 3 ECU, IPD Sway Bars, and HDTCV, Custom Throttle Body, Silicone IC hoses and vacuum lines throughout, Custom PCV.

beigg
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Post by beigg »

Great timing but unfortunate for convenience.

Drilling to 5/8" ; I think I was able to go a smidgen larger with it.
ugh smh 850 Turbo fridge

cn90
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Post by cn90 »

Glad you caught it while the car is not on highway. This could be deadly on highway.

As we all know, throttle cable technology is "dinosaur technology" as virtually all car mfg's switch to TBW (throttle by wire) around 1999-2000 or so.
Many of these throttle cables on the 1993-1997 Volvo 850, 1998 Volvo S70/V70 are now 18-24 years old.

Nothing lasts forever, and my experience with throttle cables since 1970s, 1980s, 1990s cars...replace at 140K or so. It is CHEAP insurance.
Sometimes it is seized, sometimes it is broken...both conditions are dangerous.

Well, we had a "heated discussion" on throttle cable a recently. SEE the thread below for your entertainment!

'98 V 70 -- Accelerator cable worn out?
https://www.matthewsvolvosite.com/forums ... 0&start=10
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

ACarmona
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Post by ACarmona »

Haha awesome! And thanks for the tip beigg!
My 1st Car turned first project:
1996 854R; 199k miles, 3" Angled Flange and DP to 2.5" Turboback exhaust, IPD Stage 3 ECU, IPD Sway Bars, and HDTCV, Custom Throttle Body, Silicone IC hoses and vacuum lines throughout, Custom PCV.

beigg
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Joined: 22 Sep 2013, 09:07
Year and Model: 850 97
Location: Est. Mi

Post by beigg »

Also, always be sure your parking brakes are up to snuff. I hear, if your parking brakes are in tip top shape, you're subject to waking up late for school.
ugh smh 850 Turbo fridge

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abscate
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Post by abscate »

Haha! There is an interesting split on parking brakes as in the States, where most of these cars are automatic, a lot of drivers neglect the ebrake to the point where they rust up. Then they complain of poor design.

We roll three standard transmission cars in our fleet of seven drivers so our ebrakes get cycled on all our cars
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erikv11
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Post by erikv11 »

OP, glad you had already noticed the cable was bad before it broke, have fixed this simple problem and got your car back on the road.

It reminds me of the time Robert came on here and said, "please everybody, replace ALL of your cooling system hoses now!" Including caps in the title, it was dramatic! Sounds like good, sensible advice, but horribly impractical. Of course not everyone did, and of course neither the world nor the wheels stopped spinning. The real world works with shades of gray, i.e. fix the car on schedule or when something is breaking. It is not blanket-statement black and white, if you believe that then just look at the current state of presidential politics in the USA (so fun to stir the pot! :)).
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 201k
'07 XC70, black, 205k
'07 XC70, willow green, 223k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

cn90
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Post by cn90 »

Sorry but I have to agree with Robert.
I am all about preventive maintenance, especially when it comes to cooling system (risk of overheat) and throttle cable (safety issue).

Light bubs: I don't care, I wait for the bulb to burn then replace it.
Door actuator, same thing, wait for that to fail.

Things that have significant consequence when failed should be replaced based on experience of MTBF (mean time between failure).
Aircraft maintenance is a good example: fuel pumps are replaced at ___yr/hours flown etc. etc.

Back to the Volvo...
Cooling system has its own lifespan, after ___ yr/miles the parts are simply unreliable and should be replaced for the sake of not being stranded.
Of course it costs time and money to do that. Ditto for throttle cable ("enjoy it while it lasts" is my sarcastic joke of the day b/c all modern cars are TBW).

Of course you can play the Russian roulette as you wish.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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theWIFES_S70
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Post by theWIFES_S70 »

Replacing the throttle cable was one of the best things I ever did for our car. The throttle felt so responsive, like the car had gained a few extra horsepower. if you're driving any car from the 90s with a throttle cable, it should most definitely be replaced. It's a fifteen minute swap. (On a five-speed anyhow.)
Retired:
1998 Volvo S70, N/A, 5-speed, 187K
2007 Volvo S40, 2.4i, 5-speed, 121K
2015 Volvo S60, T5, 85K

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abscate
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Post by abscate »

There are two schools of thought about PM and fix On fly (FOF) and they clash.

I run two of my cars on PM philosophy and three on FOF (another acronym made up to annoy the Dutch and the Germans)

The best is when you can run one PM and use the good old parts to FOF...not counting used motor oil.
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A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
Link to Maintenance record thread

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