weird throttle behavior - binding 1/2 way
 

This is the 240D

I think the throttle linkages are correct: pedal to the floor moves the lever on the IP to full stop.

When I move the throttle by hand, I can feel it move easily to a position that seems to be about 1/2 way down, then it feels like it "catches", and it moves the rest of the way with more resistance.

I felt the throttle action in the 300TD for a comparison, and it the resistance is consistent ant from top to bottom.

I think this is making my 240D tend to lurch a bit which I hit the acc. pedal.

Any ideas about this?

Check the ball joint on the firewall. If that looks ok (I bet $5 its the problem), then start at the IP and unhook the linkage and work your way back.

Similar to the issue I had and it was that Ball Joint on the firewall.

The PO had used a binder clip to keep the rod driven hard into the ball joint so the two pivot points would not meet and bind on each other. This, once removed, recreated the problem eventually. For some reason he had not bothered to fix it right. The "farmer fix" he had used did work, however it also made pressing the pedal a bit harder. A new Joint fixed it up nicely.

It isn't the ball joint. I disconnected the push rod that connects the lever on the IP to the rest of the throttle linkage, and the movement of the lever still had the binding. It seems to be the lever on the IP itself!

Any ideas about adjustments I can make (that don't require removing the IP!)

thanks!

Is there a shock absorber on that lever?

Our 300D's is the same way, we'll look into it in more detail at some point when our other projects are done.... :D Its probably a binding linkage or the ball joint though.

not that I can see...

Here is a pic of the relevant part. The ball on the right is where the pushrod connects, the pivot point that seems to be binding is in the lower left, and the throttle stop is top (left/center) (my idle adjustement bracket is intact, thankfully)

(credit to Forced Induction for the photo taken during dissection of an IP in an earlier thread):cool::cool:

don't forget to check to condition of the 3/2 valves "bushing" that rests against the throttle thing. some worn out "bushings" on those things cased minor binding both in application of the accelerator and in letting off, the letting off stick can be scary if you do need to stop ;)

This is a manual 240D, so it is pretty much accelerator -> linkage -> ball joint -> stop lever -> IP

And the ball is OK? Did you lube with ATF?

I will do that, but the lever still binds with the ball (and everything else) disconnected