I searched for a solution here, and unfortunately the title is the only way I know to describe it.

See pic below:

Does anyone have any tips for how to secure the choke cable sleeve in the lever assembly?  I thought about JB Welding it, but I don't want to risk getting JB on the cable itself and gumming up the works.

Thanks all.

Maybe remove the cable completely,  ream the bracket. Install the jacket and reswage somehow?

Don't know if this will help you but it made a great improvement on my '72.

https://www.ebay.com/itm/153924533662?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&itemid=153924533662&targetid=1068323858590&device=m&mktype=pla&googleloc=9012728&poi=&campaignid=11760659653&mkgroupid=112989507966&rlsatarget=pla-1068323858590&abcId=9300462&merchantid=8548804&gclid=EAIaIQobChMI2vHQqIeO8AIVjJ6zCh1oIw7EEAQYAiABEgLS5fD_BwE

Better deal

 Google it, "240z  hoke holder"

https://zcardepot.com/products/choke-lever-mounting-plate-reinforcement-240z?gclid=EAIaIQobChMImKrDpIiO8AIVdP_jBx1pNA_KEAQYAiABEgLHDvD_BwE&utm_campaign=google shopping&utm_medium=cpc&utm_source=google&variant=19278822637681

  On 4/21/2021 at 12:16 AM, Patcon said:

Maybe remove the cable completely,  ream the bracket. Install the jacket and reswage somehow?

I don't think I can re-swage something that's already been swaged...  The metal looks thick, almost like a casting, probably swaged at the factory using some industrial press.

 

Surprised to find no hits on this when I searched...  I can't be the only Z owner with this issue, can I?

 

  On 4/21/2021 at 12:21 AM, siteunseen said:

Better deal

 Google it, "240z  choke holder"

https://zcardepot.com/products/choke-lever-mounting-plate-reinforcement-240z?gclid=EAIaIQobChMImKrDpIiO8AIVdP_jBx1pNA_KEAQYAiABEgLHDvD_BwE&utm_campaign=google shopping&utm_medium=cpc&utm_source=google&variant=19278822637681

Yep; already bought that...  It's waiting to go in, but first I have to get the cable situation sorted.

Oh, I think it could be reswaged. A flat end screwdriver and a hammer or may a contraption in the bench vise, something...

It'sbroke now, so nowhere but up 😉

You can see the dents in the jacket where the swaging has compressed the material. And I believe you're right about the casting part... It looks like cast zinc or aluminum to me. Neither of which is known to be incredibly formable. And yes, that was probably swaged at the factory with a press and a fixture.

I would try to make some sort of fixture to swage the casting a tiny bit more and I would judiciously apply epoxy and give it a shot. Hope you don't crack the casting, and hope you don't get epoxy all up in there where it would gum up the works.

That doesn't look like a fun issue.

I suggest using a heat gun to soften the rubber housing enough to force it back in. 

While you have access to the choke cable itself, might as well replace the steel wire itself. 

Here's the step-by-step process:

https://woodworkerb.com/home/datsun-240z-rebuild/repair-choke-cable/

Edited April 21, 20213 yr by DatsunZGuy