Throttle cable too short

For those of you lucky enough not to have read my previous posts, I have 1 '99 c2 that has a throttle sticking issue. In my attempts to correct that problem, I have created a new one. I disassembled the throttle pedal box in order to clean and lube it. After reassembly, my throttle cable is now 3/16" too short. I now really have a high RPM at idle! The cog at the throttle body is not resting on the set screw. I assume I reassembled the cogs in the throttle pedal box incorrectly, or took up slack that should have been left alone. Is there a diagram for this box and the cogs within with any sort of directions? The rear cable is routed properly, and in place.

I would recommend to double check the black plastic-cable-retainer attached to the throttle to insure it is fully inserted

There are plenty of places the cable can get hung up by the accelerator pedal and under the car as well.

JB001 - If the plastic cable retainer is the squarish plug the cable comes through before it mounts on the round cog on the throttle body, I have checked that multiple times. I placed a mirror to see what the back-side looks like, and as far as I can tell, it's ok. Honestly though, i never looked at it before this issue, so I don't really know what it should look like. Mike - If I take the plastic undertray (?) off the bottom of the car will it expose the entire length of the cable from where it goes through the floor by the gas pedal to the joint where it connects to the rear cable?

This is how it looks like in my 99 C2 . The plastic clips must pop up otherwise it is not fully inserted.

After using my borescope to confirm the backside of the throttle body mounting plastic clip/cable connection was ok, I am thinking (hoping) that the cable sheath is not sliding into position at the throttle pedal end of the cable. Going to check this tomorrow a.m.

The saga is over! Turns out the issue with the short throttle cable was at the throttle pedal end. The cable has a metal tip that has a raised ring around its' center. That metal piece sits inside the plastic guide for the cable at the base of the pedal box, which has a female ring around its' center, but the box has to be disassembled (split) for the metal piece to be inserted and held in place. Essentially the same set-up as at the other end of the same cable where it goes into junction box for rear cable. Interestingly, it also seems to have solved the original problem of the throttle "sticking" though I am fairly certain that I created the cable issue trying to solve the sticking issue.

Thanks to all of you who helped me work through this issue!

Quotes source post: 16842964

I realize your post is 5 years old, but now I find myself with the same exact problem. I have a 1999 996 coupe 6 speed. Took things apart to replace leaking fuel lines in the engine bay. And in doing so I somehow created a throttle cable that is too short. I have had the cable in and out of the car two or three times and I'm convinced my current routing of the cable from the housing to the throttle body is correct. Everything lines up perfectly except I'm still a quarter inch or so too short. And when I start the car it tries to redline and thus immediately shut it down. If I disconnect the cable and let the butterfly close, the car starts and runs fine. So you're saying your problem was at the pedal end which I haven't really even considered up to this point since I haven't messed with that part of the equation. Would something in the peddle box account for a whole quarter inch or so of cable? Hopefully you are still around and can give me a little more guidance on how you fix your problem.

Quotes source post: 20081398

Check: 1. The plastic grommet is seated and clipped in correctly at the throttle body end. There's a photo of it earlier in the thread 2. The Junction between the two cables is assembled correctly and the outer plastic cover screwed down completely. Junction is under the car, but should still be OK if you haven't messed with it.

Quotes source post: 20081984

Thanks for reply. 1. The square grommet at the throttle body is seated and clipped in correctly. I can unclip the actual metal cable inside the sheaving from the throttle body and it moves freely in and out. Just not enough there when hooked up to fully close the butterfly. 2. I have messed with the junction under the car multiple times, and am convinced it's put together correctly. What I have not messed with is the short cable that runs from the bottom of the accelerator pedal to the junction. Attached are pics of the short cable from the accelerator pedal and the junction housing where the two cables attached. Once again just not enough length of cable to attach both ends together at the housing and then allow the butterfly to close fully. Quite frustrating!

i just swapped in a 3.4 into the 996 and having same issue... about 2 mm short so not terrible... idle it's at 1,100 rpm and if i slip my foot under the throttle, it settles in the high 800 rpm range.