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?

__________________

Current Mercedes
1979 maple yellow 240D 4-speed

Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT

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.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

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.

__________________
1983 300D-Turbo - Deep Blue w Palomino MB Tex (total loss in fire 1/5/09 RIP)
1995 E320 W124 Polar White/Grey Mushroom MB Tex
2005 F150 Supercrew - Arizona Beige - Lear topper
1985 Piaggio Vespa T5 - Black and Chrome

www.cphilip.com

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!

__________________

Current Mercedes
1979 maple yellow 240D 4-speed

Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT

Is there a shock absorber on that lever?

__________________
2001 Dodge Ram 2500 Cummins Turbo Diesel - 4x4, auto, 3.54 gears, long bed
-------------------------------------
'92 300D 2.5 Turbodiesel - sold
'83 300D Turbodiesel - 4 speed manual/2.88 diff - sold
'87 300D Turbodiesel - sold
'82 300D Turbodiesel - sold

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

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

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)

Attached Thumbnails

 

__________________

Current Mercedes
1979 maple yellow 240D 4-speed

Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT

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

__________________
'81 300D - swapped to a 617.951 turbo motor with a 150 amp alt.

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

__________________

Current Mercedes
1979 maple yellow 240D 4-speed

Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT

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

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

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

__________________

Current Mercedes
1979 maple yellow 240D 4-speed

Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT