U-240 Throttle Rebuild
Well this is a story of what to NOT do and what TO do while removing the air throttle valve under the accelerator in a 1995 U-240.
This is what not to do;
1. Crawl under the coach and disconnect the airlines attached to the air throttle. This is fine if you have exceptionally long arms, and don't mind dirt dropping in your eyes. Option 1, place a piece of plywood propped up with a 6" block to raise your body up so you can reach the airlines and wear safety glasses. OPTION 2 WAIT UNTIL YOU REMOVE THE VALVE FROM INSIDE THE COACH TO DISCONNECT THEM.
2. After removing the pedal there are three 1/4" cap screws holding the air throttle valve in place. DO NOT attempt to remove them by use of a wrench or by cutting them off with a drimell cut off blade, because if you do you still cannot extract the air throttle valve as the hole in the plate the air throttle valve is mounted to is not big enough for the valve to pass through.
What to do. BEFORE ORDERING PARTS OR A KIT, REMOVE THE PEDAL AND LOOK ON THE SIDE OF THE BOLSTER THAT ITS MOUNTED TOO AND GET THE MODEL NUMBER TO ORDER BY. Mine was WM 453 109
1. Remove the pedal by taking the keeper of the shaft and sliding the pin out.
2. Run your finger under the carpet and find the mounting plate and cut the carpet about 1" past the plate towards the front of the coach and 1 Inch past the plate towards the rear of the coach.
3. Feeling around at each corner of the mounting plate (may have to scrape away caulking) you will find one of those screws that have a 3/32" square hole in it for a driver (unless you are lucky and its a Philips head).
4. Remove those screws and the air valve and mounting plate will come up high enough to remove the air lines. Be sure to mark them.
Rebuild per the instruction in the kit and reinstall. Caulk it and glue the carpet down.
Hope this helps so you will not make my same mistakes.
Merry Christmas and have a Blessed New Year
Topic: U-240 Throttle Rebuild