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Old 05-06-2015, 01:11 PM   #1
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T7 9-5 / 9-3 Throttle Body Problems

Writing now...

Will update later.

The short story is the wires connecting the servo and the 4 potentiometers inside the throttle body have the insulation flake off after extended time exposed to the heat of the engine. Then the wires can short to each other, or to ground against the inside of the throttle housing.

And it's very difficult (or impossible) to completely disassemble the throttle body without destroying it.








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Old 05-06-2015, 05:33 PM   #2
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Soy based insulation?
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Old 05-07-2015, 10:11 AM   #3
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It looks different than what the '85 C900 harnesses do, but same problem. On the C900 the insulation gets gummy and you can peel it away from the conductor, but in the throttle bodies it gets hard and crispy and splinters off. The least little bit of movement of the wires and it all just starts disintegrating.
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Old 05-07-2015, 10:24 AM   #4
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Yes. I took one apart to see what was going on in there, found the same thing, put all the pieces in box on a parts shelf in the basement, and mentally filed it away as likely non-repairable. Although I did save it to look at later if I ever got the idea to attempt a repair or replace a part down the road...

Any ideas?
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Old 05-07-2015, 11:02 AM   #5
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Some patience and rewire the whole thing?
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Old 05-07-2015, 11:17 AM   #6
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I seem to recall someone successfully using liquid electrical tape in the past to repair it.
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Old 05-07-2015, 01:33 PM   #7
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Liquid electrical tape or hot melt glue would work if you could make sure none of the wires were contacting each other until it set up. I'd read of people doing that too.

The wires are crimped to the terminals, which are probably available from Mouser or Digikey, but just terminating new wires to the ends would work.

One of my co-workers also suggested cutting the wires in the middle and sliding heat shrink down both exposed ends, crimping the leads back together, then heat shrinking the whole thing

I did manage to figure out a way to disassemble them without breaking the housing so that you can get to the wires on both pots.

On further disassembly of mine, one of the potentiometer plates came out split in half - think we found the problem there!

I'm pretty sure all BBA does is check that the contacts on the pots are OK, and repair the wiring.

For what goes into taking one apart, it's probably just worth the $200 to let them do it, and give you the unlimited mileage warranty along with....
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