Okay, it started with a gasket replacement and escalated from there. Gasket replaced, thermostat housing replaced, fan belt replaced and manual throttle control installed. And, everything works.
The paint dried and I reinstalled the floor panel over the transmission. That lead to another small item - new transmission shifter boot covering. The original was barely big enough and it was showing signs of stress - the rubber boot was in three pieces. Luckily, the local Pep Boys has the next larger size of universal covering in stock. Perfect fit.
I did clean the threads on the transmission, coupling adapter and shift lever, 5/8 inch x 18 threads. Not uncommon, but it was a couple of stops to find the die in stock. The upside, I added a new tool to my tool box. And, after cleaning the threads it was easy to adjust the shift lever to a new position that was a shorter shift throw. By the way, this is not a stock Jeep transmission. It is an NV-4500 which requires some clearance adjustments to fit.
With everything mounted inside, attention turned to the engine and addressing the cable end bolt mounting options. And, the instruction said, drill a hole and mount this bracket. After looking at the configuration, I ask myself "Why? It can be mounted a simpler way."
The throttle cable feeds through a bracket bolted to the engine. The bracket already has holes (square). Why drill another hole? The item to be mounted is the special bolt that positions the cable sheath and feeds the control cable through to attach to the throttle.
My spare parts drawer yielded a 90 degree angle bracket. That, along with a washer would cover the square hole and provide sufficient stabilization to hold the cable mounting bolt in position. I did need to drill a hole in the part bin angle bracket.
Once mounted, I secured the cable sheath along side the throttle cable, cut to length, and threaded the control cable through the sheath. The kit included a ferrel that secured the cable loop. For that, you need really big pliers to provide crushing leverage.
Install done. Time for the crucial test, after reinstalling the air intake tubing. Engine started, no squeal from the fan belt, and the manual throttle provided a easy, convenient way to increase idling RPM.
The manual throttle kit is marketed by TerraFlex as a universal kit. Depending on your vehicle, your mounting of throttle controller and the cable end bolt may require some creativity. My Jeep (94 YJ) had sufficient interior room to mount the controller bracket just ahead of the transmission shift tower. And, the mounting for the cable end bolt used the existing hole meant for a cruise control cable.
I have a 2010 Jeep JK and it would be difficult to find a convenient mounting spot for the controller and cable routing would be a challenge. Three points to consider with this kit: 1) controller mounting, 2) cable end bolt mounting, and 3) cable routing. Jeep YJ and CJ models are easy. The mod is functional and easy to adjust. The throttle control does have a lock screw to tighten and maintain your desired setting.
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