Throttle Position (TP) Sensor: Removal

All engines 

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .

   4.0L SOHC engine 

2. Disconnect the Throttle Position (TP) sensor electrical connector.
   Fig 1: Locating Throttle Position (TP) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
NOTE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
3. Remove the TP  sensor.
   1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP  sensor bolt ear reaches approximately 55°C (130°F). This should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the ETB  .
   2. Monitor the temperature of the top TP  sensor bolt ear on the ETB  with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB  .
   3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
   4. Using hand tools, remove the remaining bolt and discard.
   5. Remove and discard the TP  sensor.
      Fig 2: Identifying TP Sensor Parts

      Courtesy of FORD MOTOR CO.

   4.6L (3V) and 5.4L (4V) engines 

4. Disconnect the TP  sensor electrical connector.
   Fig 3: Locating Throttle Position (TP) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
NOTE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
5. Remove the TP  sensor.
   1. Using a suitable heat gun, apply heat to the top of the ETB  until the top TP  sensor bolt ear reaches approximately 55°C (130°F). This should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the ETB  .
   2. Monitor the temperature of the top TP  sensor bolt ear on the ETB  with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB  .
   3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
   4. Using hand tools, remove the remaining bolt and discard.
   5. Remove and discard the TP  sensor.
      Fig 4: Identifying TP Sensor Parts

      Courtesy of FORD MOTOR CO.