BC Throttle Cable Breakage

This is my second BC Broncos throttle cable failure and I am posting some pics for review. I suspect I am doing something wrong in my install to cause these failures.

The angeled washers on the firewall are in the correct position as per instructions as best I can tell.

One of the things I am wondering about is the sheath is so long it has to make the bend you can see in the pics, could that be contributing to failure.

Both inner cable breakages have occurred between the gas peddle and firewall as can be seen in the pics.

Other than two failures in a couple of years it has worked great, no sticking and has felt smooth as silk, even the second before failure.

So take a look and give me some ideas, and if you would please Chuck, send me a replacement along with any advice you can offer.

i just replaced mine for breakage in the same place. it looked exactly like yours does. I figured out that the angle wasn't perfect and the cable rubbed on the end of the threaded part on the bottom when I went from no throttle to any amt. I had to take the ball part off the pedal rod and hammer it flat against the anvil on my vise about 1" past where it is already flat. drill new hole lower and now the cable comes out flat. from what I can tell from your pic the angle looks good and don't see a grove cut in the end of the threded part. I could see a grove cut into mine that is how I new what the problem was. when you replace the inner cable watch where it comes out real close as you go from no throttle through the full range and make sure it is in the middel of the end and not rubbing. I also had to bend mine over just a hair so it wasn't rubbing the side too. That's the only experience I have had with mine breaking

Breaking there is caused by the cable being bent. I think what is happening in your case is when you let off the pedal moves faster than the cable. A stronger spring should fix the problem. Also be sure the cable goes into the center of the sheath at both ends. Also be sure the cable end moves freely on the ball.

It looks like you have to sharp of a bend coming out of the firewall. I cut mine so it wouldnt have that bend in it. It looks like it may be getting in a bind there. Mine is a Lokar but it looks just like yours. Ive had it a few yaers and have no problems so far.

I have a BC throttle cable and I drilled an angle hole into the piece that clips onto the pedal assembly. That way I can actually thread the cable through that piece and then tighten it down with the screw. It has worked perfectly for over a year.

i've had my BC cable fro a good 3 years now, i have no problems with it. i'm not even using the angled washers.

had mine a year now but the bronco rests in garage most the time!no promblems so far

Ordered my inner cable this afternoon, about twelve bucks plus shipping.

Thanks for the tips