Throttle Position Sensor removal issue

KoRnyBrad · **Posted:** Sat Jan 18, 2014 5:23 am

I'm trying to change out the TPS on my 02. For the life of me I can't get the screws to loosen! I'm using a torx 20 bit. I've used a screwdriver with bit, socket with bit, and even a torque wrench! I've tried everything to get it to loosen but can't. I'm afraid I'm going to strip it out. Anybody had trouble with this or got any pointers? Thanks in advance.

02blue · **Posted:** Sat Jan 18, 2014 12:39 pm

I replaced mine a few years back and it was a bear. Mines an 02 and T-20 is right. Very tough to move. Be patient and apply very even pressure so you don't snap it off. Get a longer handle ratchet if possible for some more torque. Thought mine might have been thread locked in there.

streetglideok · **Posted:** Sat Jan 18, 2014 2:10 pm

Use a high quality torx socket, not anything with the Lisle name on it. On some vehicles due to the car maker using Loctite on the screws, they recommended using some heat to relax the Loctite and avoid a broken screw.

02blue · **Posted:** Sat Jan 18, 2014 2:57 pm

Good point on the socket. That's what I used, not the little nutdriver adapter you'd use for trim/taillight removal. I have a pretty heavy duty set and a long handled ratchet for torque. Remember, gentle. Wish I'd of thought of a little heat. Great tip.

When I swapped the throttle body on my Ranger I actually had to drill the heads off the TPS to swap it since Ford used some Rivet looking bolt. Believe it or not drilling them off was the standard method to remove. BBK supplied new bolts with the bigger TB. So it could be worse.

KoRnyBrad · **Posted:** Sun Jan 19, 2014 1:28 am

Coworker suggested heat as well. But is putting heat near the throttle body a good idea?

02blue · **Posted:** Sun Jan 19, 2014 6:30 pm

I'd just try a better Torx socket first with more even torque.

As for heat, shouldn't really be any super volatile stuff up there unless you've got a leak. Caution is a good thing! Could place some shielding material. You'd want a very focused heat source since the sensor and lots of other stuff up there is plastic. Might even try a heatgun or hairdryer. That might be enough since I think you just want to warm it a bit. If you are reluctant you can just pull the TB off and work on it in a vice.

I'd just try more torque, but evenly applied.

KoRnyBrad · **Posted:** Sun Jan 19, 2014 11:30 pm

Thanks 02blue, I'll give it a shot.

RockRollin · **Joined:** Sun May 20, 2012 7:51 am **Posts:** 5

Soldering iron works well to heat "micro" parts only. It is a bit slow though. Also nothing beats shock for thread lock AKA hammer, just dont get crazy, and keep (gentle) blows in line with bolt/screw.

02blue · **Posted:** Mon Jan 20, 2014 9:10 am

RockRollin wrote:

Also nothing beats shock for thread lock AKA hammer, just dont get crazy, and keep (gentle) blows in line with bolt/screw.

Great point! Even a gentle tap can rattle those molecules. Just a gentle tap straight on for a little vibration.

Throttle Position Sensor removal issue

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