Hi guys.

My throttle pedal was going dead off idle, 03, 7.3 Diesel, and I have the adjustable pedals. As you know prices range from $580 to over $1000 for this assembly.

Being the geek that I am I took the throttle pedal assembly off the truck and put it on the bench. R&R takes a whole 3 minutes.

Inside the assembly are two sensors, the TPS as well as the IVS. I tested the pins and found that the IVS was causing the problem. With the multimeter the readings were all over the place jumping and the audible portion was screeching like a bad vinyl record.

Carefully ground off the plastic pins on the side and the cover popped off. Inside there are two tracks that the arm moves against Each of these have small brass arms that make contact with the "metal scales"

Clearly the IVS was very worn down and had grooves in it to base plastic. This was the cause of the IVS failure and spotty throttle. The TPS was in great condition.

The good part is that the strip it rides against is twice as wide as required.

What I did was take a small jewelers screwdriver and gently pried the arms apart, spread them, so that they now ride on the brand new fresh surface.

Popped it back on the meter and all was good again. Cleaned the surface and applied new die electric grease, resealed the cover with silicone, placed the cover back on, and hot glued over the rivets.

Throttle response is better and believe it or not fuel mileage went up by about 1 mpg too.

I had nothing to lose doing this as the alternative was to spend the big bucks.

This should last another 150K :-)

Sorry about no pics. Hope this helps someone .

Might want to add it to tech.

 

Very nice post, thanks for sharing.

 

You are welcome :-)