The non E-Gas has the cable on the bottom running to the throttle body and, if equipped, a cable on top running to the cruise control. What a pain to remove/install if you have cables at both ends...

 

so, I have not gone and checked mine for operation, but a couple weeks ago I had the wierdest throttle feeling, then I got irratated and floored the gas... something "clicked" and it worked smooth as butter. From your pics, my guess is that my cable came out of the track and that might have been caused by side to side action on the pedal...

Great info, I will check into it. Thanks for the write up (old but worth hanging on to)

 

I went through the same thing not long ago.

After completely rebuilding it my advice is try lubing first without taking it all apart. You can hit all the necessary parts with lube by just squirting it in there.
Just use some needle nose pliers to pry the little ball out of the socket, push the tabs on the back of the pedal and pull it off. Then you can pull the boot out and see where you need to lube.

I used liquid teflon type stuff that drys up and leaves a coating of teflon, so it shouldn't hurt anything to just squirt it all over the parts.

As for the side to side slop, I fixed mine a little differently, I used mounting tape. The pedal can be removed from the hinge without taking everything out.
Mine was really loose. The little 'springs' at the top of the hinge part were bent.

While I had it apart I worked the lube down into the cable but I don't think that was really necessary. It has it's own coating.

 

Thanks Van and Couper for the excellant writeup and photos. I did this a few days ago and mine is an '03 e-gas, which has only one but major difference.

I found that the majority of the friction is actually from the ball joint on the gas pedal that accepts the metal rod (see black arrow in the photo)....and I think it's by design.



It turns out '03 and up has a 3/8" c clip that "squeezes" the ball joint and tighten it up (see photo below).



I acceidentally knocked off the c clip during re-assembly. With the c clip gone, the pedal is as smooth as silk and I LOVE it!

More googling of e-gas pedal patents reveal that artificial friction is used to mimic the feel of the traditional mecahnical gas pedal. There's also mentioning of the need to add hystersis so the car won't stumble on very bumpy pavement. I drove the car a few days and found no side effects...just smiles on my face and much easier feathering of the gas and the clutch.

 

Great to know, Ahsai. Thanks for sharing!

 

Thanks for your inspiration!

 

I am pleased to report that for me the lube-without-disassembly approach worked wonderfully.

I've been driving barefoot recently around town and noticed I had some minor stickiness while part throttle cruising. Nothing major, but I could feel it.

I took some "CRC Heavy Duty Silicone" spray and with the needle attachment sprayed the small ball joint connection near the middle of the pedal and the hinge at the bottom.

Markedly better and very smooth now.

I used an inspection mirror and I too have this C clip in my 2004 C4S.

Thanks again to everyone who posted with instructions and pictures.

 

I'm bringing this up to the top as I just did this DIY, and the pedal on the GT3 works perfectly now!

Gotta love the info sharing on Rennlist! Thanks all.

 

Thank you sir. I know this thread has been around for a while, but it's clearly still useful !! I suspect many of these cars actually need this without the owners even realizing it. Improved drivability significantly !!!
Cheers,
Brendan

 

By the way, this post is still highly useful! Just performed this on my 2000 996 because of a gas pedal that just wasn't the "right feel". Pulled the pedal out as per all of the awesome pics and posts on this topic, opened it up, cleaned everything, sprayed it sparingly with some white grease and put it all back together. Although I must admit, putting the pedal back together is the biggest challenge; several parts which all have to go back together at the same time requiring a bit of patience! Worth it though. Thanks all!!!

 

Funny, I'm in the middle of the same project. Getting all of the parts back together is definitely a challenge. Do you have any tips for making sure the cable running to the throttle is properly placed in the pedal? I'm having a very difficult time getting the end of the throttle cable to seat properly inside the pedal assembly ( at the bottom of the pedal ) ? My throttle cable is quite short and does not come above the level of the carpet.

BTW, this doc has some pictures of the inside of a non-egas pedal... http://www.rennline.com/PDF/A13_install_PG1,2,3_web.pdf

 

I'm apparently not as clever as most here........what technique do you use to get the ball back in the socket on the backside of the gas pedal when the pedal is still in place?

Addendum....I am putting on RennLine pedals; when I tried to back the drill bit out, the pedal was pulled off the ball on my '01.

 

RE: the clip - any chance that clip is there to ensure retention of the ball? I have not checked out the assembly myself - are there other physical stops that ensure the parts stay connected? Losing the ability to accelerate because the ball pops out of the socket would be a bit of a drag...

 

As far as I remember, the ball stays in pretty tight even w/o the clip. Once connected, it's not going anyway. I guess unless you intentionally pull up the gas pedal trying to rip it apart from the assembly. But check it by yourself and use your own judgement...

 

I have a 99 with the cable at both ends. I am working on removing the carpet due to a clogged sunroof drain. How does the throttle cable remove from the bottom of the pedal?

Does anyone have instructions on how to remove the ebarke to get the carpet out? I have read the instructions on Pelican and they don't really address what you should or should not remove from the ebrake to get the carpet out.

Thanks,
Alex