Accelerator Linkage and Pedal Improvements

Discussion in 'Bay Tech Clinic' started by Melb.VDubber, Jan 31, 2014.

  1. Melb.VDubber

    Melb.VDubber Member

    Messages:
    156
    Location:
    Melbourne
    Hi All,

    I've been lurking around on here for a few years soaking up information while I got our bus ready for the road so I thought it about time I gave something back and hopefully it can help somebody out.
    I brought Sunny about 2 years ago from a fellow KC Member, he was a good solid bus but was in need of some rust repairs and some serious TLC. He's a 74 Bay 1800 auto, he was in far from roadworthy condition but we (finally) in the last 2 weeks got him registered and out on his first adventure with our family on the Australia Day weekend!

    I've been a watercooled VW fan for many years, owing a raft of Golf GTI's so when it came time for a mobile holiday machine there was only one choice of course and it had to challenge me so a 'proper' VW it was!

    Anyway I digress slightly and after our first road trip I was slightly concerned about his performance or total lack of, and after reading many posts about travel and top speeds, decided that something simple must be causing his issue. I knew he was mechanically A1 with pretty much everything you can bolt onto the engine being replaced or refurbished. So I went looking. I'd just like to add that I'm a diesel mechanic by trade so petrol fuel and ignitions can be challenging at times, but the posts and advice by many members on here and I would like to say especially from 1500king have been a first class resource. His dual carb set up procedure was so simple and straight forward and provided me with the perfect set up first time. So thanks to you all. It really is a wonderful forum. Anyway I'm waffling off topic again...

    So after deciding that a simple issue was causing my problem I decided to check full throttle first. So I got Mrs W behind the wheel and got her to hold the old boy flat to the floor

    WP_20140129_17_54_45_Pro.jpg

    That pretty much summed it up. Half throttle with the foot flat to the floor!
     
    1500king likes this.
  2. cbus

    cbus Well-Known Member

    Messages:
    10,273
    Location:
    sunshine coast
    fairly normal :)
     
  3. Melb.VDubber

    Melb.VDubber Member

    Messages:
    156
    Location:
    Melbourne
    I had replaced the accelerator cable and all the linkages and pedal, I knew play was not causing my issue. So i decided a longer stroke would fix my problem. So i knocked up a fairly ordinary bracket in the garage to test it out. Bracket made I promptly got Mrs W back for pedal duties, low and behold I'm still not getting full throttle. Slightly bemused and a little confused I started on a round of practising some high school geometry to work out the perfect length for my lever extension to give me full throttle. After about two hours of trial and error I was still unable to go all the way! I was getting confused! :eek:

    WP_20140129_17_59_59_Pro.jpg

    It was only when Mrs W was out and not being able to hold the pedal down did I inadvertently find the cause.

    I removed the s linkage from the pedal so i could jam a brick on the linkage end to hold it down flat out. After checking again I all of a sudden had full throttle. So i reconnected the pedal and it finally hit me. At some point the drivers side floor had several patches put on including where the pedal mounts and when the pedal had been refitted the geometry had been totally messed up. A few more measurements and a couple of new holes later and I finally had full throttle! Man was I excited.

    So I quickly threw the rest of the bus back together and cracked on for a road test, backed out of the driveway and took off around a tight bend (very quickly) and I got a bit of wheel spin!!!!!
    We live in a hilly area and he was a new man, so off I continued to test him out on the open road. I hit the freeway which is fairly close to our place, you could not wipe the smile off my face as i backed off well over 100kph!

    We are taking him on a 2 week adventure at the end of next week and now I simply cannot wait. So if you are struggling to find some missing power these two simple checks may well be worth a look!

    Thanks and look forward to seeing you on the road.

    Matt
     
  4. oldman

    oldman Super Moderator Staff Member

    Messages:
    7,381
    Location:
    Avalon Beach NSW
    Goodonya Matt !! Nothing as rewarding as a simple, effective fix :cool:
    Thanks for posting your experience.....it'll only be a matter of time before someone will benefit....that's how the kombi spirit is passed on.
     
  5. 1500king

    1500king Well-Known Member

    Messages:
    1,435
    Location:
    Adelaide, SA
    for you!! LOL!
     
  6. Blunderbus

    Blunderbus Active Member

    Messages:
    513
    Location:
    St Helena, Melbourne .
    Yeah the hills around here have the old bus dropping into lower gears so might be worth checking the linkages out.
     
  7. chenko

    chenko Member

    Messages:
    174
    Location:
    Sydney
    what is this 100 kph you speak of?
     
  8. Alpal

    Alpal Moderator Staff Member

    Messages:
    7,964
    Location:
    Melbourne Bend of Islands
    Others have found the layers of carpet etc under the pedal impare the travel. Worth a look down the carb to see if opening fully. Instant GT!
     
  9. Micky O

    Micky O Member

    Messages:
    51
    Location:
    Blue Mountains
    Hey Matt, I have the exact same problem in my 75 bay auto. Pedal flat to the floor means the carbies are only half open!

    I see another poster had the very same issue in a 75 bay. It must be something to do with the accelerator mechanism around that time - this is the period when the pushrod is located roughly in the middle of the pedal. (Less than a year later, such as my other kombi which is a 76, they had changed the mechanism so the mechanism joins right at the front tip of the pedal.)

    Anyways, I digress. You seem to have fixed the problem, but I am not exactly sure how you did it! I have made sure there is absolutely no sloppiness in the pushrod and linkages, and there is only bare metal under the pushrod. But I just can't see how I can get more movement in the mechanism, short of cutting a hole in the floor. Did you move the pedal forwards or backwards perhaps?
    Micky
     
  10. KombiMadness

    KombiMadness Well-Known Member

    Messages:
    1,707
    Location:
    Sunshine Coast
    Yep, easy & low tech fixes are always satisfying.....

    There have been a lot of owners with throttle issues over the years. Surprisingly, since the VW engineers did such an amazing job with so much of the clever design innovations of the T2 - the design of the pedal, pedal hinge and S linkage is crap! It has way too much lateral play, can bind and a slight bending of the actual pedal (or floor) has a major effect on effective throttle. One of the other 'good & simple' fixes is replacing the S linkage with mini ball joint rod ends. This eliminates the lateral play and gives a much smoother action. I think there is even an old thread here on KC about it. I had to source them from a specialist engineering supplier to get them small enough but they were cheap.....

    [​IMG]
     
  11. Micky O

    Micky O Member

    Messages:
    51
    Location:
    Blue Mountains
    Oo yeah! I sourced one of those pushrods with the little bearings in them (about $40 at JK), and it does do an amazing job of removing the play in the accelerator pedal. That's what had me totally stumped, because it didn't make any difference at the carby end.

    However, since this morning when I posted, I have FIXED the problem. Hooray!

    Basically, there was too much play in the cable. This might be because the cable had stretched a little, but more likely it wasn't the correct cable to begin with! Curses to the previous owner. So, I improvised a spacer at the back using a couple of washers and just the right length of metal curtain rod ...
    20161218_151528.jpg

    ... and voila, it's brilliant! I have a new kombi. 100kph here I come!
     
    KombiMadness likes this.
  12. Woolly

    Woolly Member

    Messages:
    40
    Location:
    Brisbane
    Bit late on this post but try butty's bits (UK based but Red Wolf in Australia import) new linkages - put one on my 72 cross over and it is brilliant - well worth the $150 and easy to fit yourself.
     
    Gordon D likes this.
  13. Micky O

    Micky O Member

    Messages:
    51
    Location:
    Blue Mountains
    Yeah, thanks for the info. Butty's Bits looks like a very handy site.

    The throttle kit looks identical to what I got in the end. The main difference from the original throttle mechanism is the pushrod with the little ball joint bearings instead of the S-shaped rod. I got just such a pushrod from JK for about $40, and it effectively eliminated all play in the pedal. It's now perfect.

    In the end, however, it turned out that my MAJOR problem was at the carby end! The darn cable was fractionally too long, meaning that the first half a press of the throttle did nothing at all to the carbies. I rigged a solution - see above - and it now works a treat. I have a new bus!
     
  14. Midlifecrisis

    Midlifecrisis Member

    Messages:
    37
    Location:
    WA
    Hi all, I bought a set of the rose joints for my accelerator pedal but when I examined my set up fully I found that I didn't need it. I just adjusted the throttle cable and have taken out most of my slack.
    So I have a set of these rose joints if anyone wants it ($32 plus $8 postage).
    Please pm me if interested.
    I'll send you a picture of it and the receipt showing I paid for it on 24/04/2017
     

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