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Old 07-29-2007, 07:59 PM
cdplayer's Avatar
Just my Jeep and my S500
 
Join Date: Aug 2006
Location: Sacramento, Calif.
Posts: 581
Adjusting Boden cable on a gasser

A couple of weeks ago my kickdown stopped working. I changed the relay with one I got at the junk yard for two bucks. No affect. I checked all the fuses. Fuses ok. So I did a search here, several actually, and found many posts for adjusting/replacing the Boden(kickdown) cable. But all the info covered only diesel cars. So off to the junk yard!

The bad news is that I destroyed a perfectly good boden cable trying to get the plastic lock to release at the tranny. By the way the cable(which there are several at this junk yard) is only $7.99!
Keep in mind I am on my back under an 84 500SEL in 95 degree weather. I saw pics of new cables from the parts suppliers, but still could not figure out how to release the cable from the tranny. Finally using pliers on the plastic sheath, I was able to twist and tug the cable free. I then dropped the pan to see what the cable activates when pulled by the accellerator cable. The cable attaches to an L shaped rod which activates a lever that pushes in a plunger inside the tranny pan and walla! kickdown.

The good news is that my kickdown problem was not a broken cable, as I had thought, at all. I discovered(see pics) my adjustment rod had slipped.
Adjusting a gasser cable is very different than a diesel cable.
Many junk cars still had their boden intact so I learned how the cable was supposed to be adjusted. Near the back of the air breather is the throttle linkage. The throttle has a domed shaped metel piece as does the boden cable linkage. And just above them is a slip rod with a tightening screw.
Somehow this screw allowed the rod to slip and the domed parts of the throttle and boden cable were misaligned.
These domed shapes must align. As the gas pedal is pressed the domed part of the throttle moves toward the passenger side of the car. And so must the domed part of the boden cable. As the throttle increases the tug on the boden cable also increases until kickdown is achieved.
I discovered with my misaligned cables, I had full throttle, but the boden cable had not been fully extended. Therefore the plunger inside the tranny pan never got activated.

Attached Thumbnails
Adjusting Boden cable on a gasser-500sec-022.jpg   Adjusting Boden cable on a gasser-500sec-021.jpg  
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