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Replacing A TPS With Damaged Screws, How To

Discussion in 'Stock 1995 - 2001 Explorers' started by 239, June 29, 2019.

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  1. 239

    239 Active Member

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    City, State:
    Bonita Springs, FL
    Year, Model & Trim Level:
    2000 XLT, V6 OHV
    A couple of years ago I got the idea of replacing my throttle position sensor since it was the stock part. I gave up after rounding the philips screws. I then tired to use a dremel to cut a slot into the screw heads but that didn’t work out too well.

    Recently, my absolute throttle position would be different every time I drove the truck. Sometimes it would be at 18.8% and other times as high as 21%. I finally purchased a dremel torch to heat the screws and proceeded to destroy the old tps.

    9F3A5FF8-D055-466A-8BF8-06892D521C0A.jpeg

    From here I applied heat and then began to turn the screw with some vampliers.

    FBC004EC-4A4C-4765-80B7-9782AE7F513E.jpeg

    The round part of the pliers grabs on great and fits snug on the screw heads. Finally, I had removed the old, faulty sensor and had a Motorcraft replacement on. My absolute throttle position is always at 18.4% now, at idle. I used bolts to replace the philips screws this time. The size of the bolts are
    5x30x.80 and are the same on the SOHC, from what I saw on YouTube.

    B838081C-45D6-4EA5-9123-0BFF83B57788.jpeg

    My throttle response is better now and acceleration is too, which really surprised me when I first drove with a new tps. I read about testing the tps with a multimeter but I could tell mine was bad just by watching it on my blue driver obd scanner.

    The parts I used were:
    Throttle Position Sensor 2000 OHV: CX1542
    Pliers: VT001
    Bolts: Stainless 5x30x.80
     
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  3. XLTrunner

    XLTrunner Active Member

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    Nice work-around! I don't know why those screws are always so tight. I've had to grab the edges with a small vise-grips sometimes to get them loose.
     
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  4. koda2000

    koda2000 Explorer Addict

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    Steel screws in aluminum tend to be tough to break loose (due to electrolysis of dissimilar metals). The longer they're attached the harder they are to break free.
     
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  5. RandomNerd2000

    RandomNerd2000 Well-Known Member

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    ^This. I repair lawn equipment and that's the number one pitfall that old equipment has, heat, moisture and time does em in.
     
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  6. 239

    239 Active Member

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    City, State:
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    2000 XLT, V6 OHV
    Yeah mine were definitely in there good. The loctite made it 10x worse. Hardest screws I’ve had to remove. Bolts are an improvement for sure.
    059B189C-75A2-4A0A-9D22-4A40E30410DA.jpeg
     

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