Been digging into some lingering performance issues over the past couple of weeks, and noticed something odd regarding the TPS. Measurements have been taken using Torque Pro and an ELM327 Bluetooth OBD-II adapter.

Foot completely off the pedal, it's showing as 10% pressed.

Mashing the pedal to the floor, it's showing as 90% pressed.

Before I throw parts at the problem and order a replacement accelerator pedal assembly, are these numbers considered normal? I would expect to see 0% and 100% at the extremes of travel, but the numbers suggest that ±20% of the possible sensor range may now be gone.

Through the readable part of the range, the values do seem to change smoothly as the pedal is pressed or released, so it appears that this is only an issue at the extremes of travel.

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2005 KJ CRD Limited 4x4:
245/75R16 BFG TA KO2s
OME / Clevis 2.5" Lift
JBA Lifted A-Arms
IRO WJ Short Rear UCA/WWDiesel mount
Skid Row Skidplates
HDS Model 001 Thermostat (190°F)
Suncoast TC
Full Weeks Kit
Bosch 5V glow plugs
Hayden 2986 fan clutch / GM 11-blade fan
Samco / Sasquatch Intake Hoses
Carter in-tank pump
Provent 200
V6 Airbox

Looks perfectly fine to me.

Its just a variable resistor.
All variable resistors can vary + or - 100 ohms on either end.

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U.S. Army Retired

Which is true, but losing 20% of the total range seems a bit excessive to me. Then again, I don't know what the total range of resistance is that it has, so it may not be as critical as I'm thinking it is.

Kinda feeling like at 160,000 miles it couldn't hurt to replace the sensor, but it's not cheap or easy to come by and hasn't obviously failed. Also don't want to go down the rabbit hole of obsessively repairing or replacing everything that looks to be 0.0004% out of tolerance

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2005 KJ CRD Limited 4x4:
245/75R16 BFG TA KO2s
OME / Clevis 2.5" Lift
JBA Lifted A-Arms
IRO WJ Short Rear UCA/WWDiesel mount
Skid Row Skidplates
HDS Model 001 Thermostat (190°F)
Suncoast TC
Full Weeks Kit
Bosch 5V glow plugs
Hayden 2986 fan clutch / GM 11-blade fan
Samco / Sasquatch Intake Hoses
Carter in-tank pump
Provent 200
V6 Airbox

If its not broke, dont try & fix it!
The low end should not be a problem unless it has a very high idle RPM. The top end will only be an issue if you cant get WOT (wide open throttle or full throttle).
I suspect it has settings so that it doesnt use the full range.
If you wanted, you could try cleaning the mechanism, but there is a strong chance of damaging it.

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Australian KJ CRD 2006