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I just installed a new throttle cable (OE sticking) in my 98' F-150 SC 4x4 with a 5.4L. The new cable appears to be a little longer installed than the original one. At the throttle body I pushed down on the bare cable in the area right before it attaches to the TB drum and it went down about 1 1/2 inches. Also, the snap that holds the cable into the pedal assembly would come out of it's square black plastic clip causing it to catch prematurely before seating properly.
I adjusted the cable by bending the steel back tab behind the accelerator pedal slightly forward or towards the seat to take out the excess. Now there's about 1/2 inch free-play at the throttle body (vertically pushing down on the cable) and about a 1/4 inch at the pedal horizontally. I called a local Ford dealer to verify this spec., but the techs. were gone for the weekend. Did my procedure sound correct to you Ford techs.?
I also cleaned and lubed the throttle body shaft with some WD. Works great now without excessive idle and idles in drive with brake on at 525 rpms.
I'll have to double check that full throttle is being achieved. I did read about other similar trucks having this problem with the newer cable and some of them were just crimping stoppers on the cable. I thought that was crude and did not go that route.
hell, some people are putting zip ties on the end.
After reading those attempts, I briefly thought an 1/8 once slip-shot would do, but no way.
Why are they tooooo long anyways? I suppose, they are made in Mexico. I also had to twist the cable 180 degs. to make the bolt line up with the throttle body mounting hole. They're smoking something down there.