UPDATE: I finally found my old thread.... MY problem is fixed, was reading a thread from another site, and decided to try his trick. This is not my idea, but I used it, and want to thank who ever it was on the other site.
I UNPLUGGED both throttle pedal connectors (yes i have 2 early model 99) and cleaned the pin connection with WD-40 then plugged and unplugged them a few times to be assured that any green tarnish or corrosion is rubbed away, then reconnected them and used some electrical grease. I also sprayed in around on and anywhere else I could get some WD-40 to go on both the TPS and the IVS. That has been about 6 months ago, and still working good.
Now onto the next project. Injectors, glow plugs, 50 cent mod. RDP fuel rail cross over and new o rings on the fuel bowl. Needless to say this is more than just a weekend job LOL Hope this helps someone out there with that surge problem.

 

Thanks for the update.

 

I have replaced 3 of these pedals 2 during vacation trips.

I have a 2001 Excursion with the 7.3 all stock. Today I finally had enough and opened 2 of the three I had in a box by drilling out the "MELT" fasteners.

There are 4 carbon acrylic traces with wipers acting as variable resistors and attached to a plastic bar. Upon inspection it appears that white grease from the top of the plastic arm contaminated the traces and caused intermittant contact hence surging of the throttle.

After cleaning the grease with circuit board cleaner and restoring the pedal to service, it works great.

This ends the long 6 year saga of reading posts and testing sensors.

I did learn so much over the years that it has been a positive experience in the final analysis.

I took some pictures of the inside of the pedal wiper board but don't see a way to insert them yet.

Thanks for all the info and friendly interaction at this site.

J. Horil

 

thanks for the update,maybe somebody more knowledge with pics will chime in.