Slowly I am pulling my hair out...

Last week I had the interesting experience of the throttle cable
seizing almost solid on a trip around the M25 - to the extend that the
throttle pedal (fiesta) was mashed to the floor and twisted like a
pretzel entirely against the friction of the cable.

Today I fitted a new pedal - from a sierra; it has the same cable end
but different mountings and looks a lot tougher - carefully ensuring
that the cable end through the bulkhead was organised nicely to be
straight. The cable was a new (pattern) part supplied by Quantum
though it has the same markings as the pattern part I removed.

The cable pulled smoothly on the pedal; the carburettor moves easily
at no more than finger pressure, and the connector is aligned and
moves nicely with the cable. The pedal is easily moved by hand, with
the obvious over-centre feel as the first throttle opens then linear
over the second.

So I take the car for a test drive. To start with, everything is fine.
It's not the scalded cat effect I would like but it's obviously
startled, and for the first time since owning it I've actually been
happy to consider overtaking something on a single carriageway road.

Woohoo.

And within ten miles, the problem is back. Nasty graunching noises and
a really rough pedal feel and much stiffer than when I set off.

Take it all to bits, everything's free. Put it together, graunch
graunch friction and stiffness... I am not a happy bunny.

The only thing I can think is that the cable doesn't like making the
180 turn over the cam cover. As far as I can see, the carb end is
nylon sheathed on the inner, but the pedal end isn't so I'm wondering
if it's simply wearing steel on steel where the bend occurs... and yet
I can't see why there should be such a huge pressure there.

I'm stuck. I'm completely out of ideas, with the sole exception of
going around to Sky Ford and buying an official part... any clues
gratefully received!

Neil
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