This procedure covers the removal and replacement of the throttle position sensor (TPS) on the 3.5L EcoBoost V6 engine, including proper calibration steps.

Warnings

Tools required

Parts

• Throttle Position Sensor × 1 — Use OEM specification - Motorcraft DY-1184 or equivalent

Preparation

1. Park vehicle on level ground and apply parking brake
2. Allow engine to cool completely before beginning work
3. Disconnect negative battery terminal and wait 2 minutes for system depowerization
4. Relieve residual fuel pressure by briefly turning ignition to ON position (do not start) after battery disconnect

Procedure

1. 1

   Access the throttle body assembly
   Remove the engine cover by pulling upward on the cover to disengage the retaining grommets. Locate the throttle body on the driver's side of the engine, mounted to the intake plenum. The throttle position sensor is integrated into the throttle body assembly.
2. 2

   Disconnect the air intake duct
   Loosen the clamp securing the air intake duct to the throttle body inlet. Disconnect the mass airflow sensor electrical connector by pressing the release tab and pulling straight back. Remove the air intake duct and set aside.
3. 3

   Disconnect throttle body electrical connector
   Locate the electrical connector on the side of the throttle body. Press down on the connector lock tab while pulling the connector away from the throttle body. Inspect connector pins for corrosion or damage.
4. 4

   Disconnect coolant hoses
   Using hose clamp pliers or a flathead screwdriver, reposition the spring clamps on both coolant bypass hoses connected to the throttle body. Have a drain pan ready as small amount of coolant will drain. Carefully twist and pull the hoses from the throttle body ports. Plug the hoses with small plastic caps or wrap in shop towels to minimize coolant loss.
5. 5

   Remove throttle body mounting bolts
   Remove the four throttle body mounting bolts using a T20 Torx bit or driver. Note the bolt positions as they may be different lengths. Carefully pull the throttle body assembly away from the intake manifold. Do not pry against the intake manifold sealing surface.
6. 6

   Remove old gasket and clean surfaces
   Remove and discard the old throttle body gasket from the intake manifold. Clean the intake manifold sealing surface thoroughly with a plastic scraper and clean shop towels. Remove all old gasket material and debris. Do not allow debris to fall into the intake manifold opening - cover with a clean shop towel while cleaning.
7. 7

   Install new throttle body assembly
   Position a new throttle body gasket on the intake manifold. Align the new throttle body assembly to the gasket and intake manifold, ensuring the coolant ports and bolt holes are properly aligned. Hand-thread all four mounting bolts before tightening any. Tighten the mounting bolts in a crossing pattern to the specified torque.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
8. 8

   Reconnect coolant hoses
   Push the coolant bypass hoses firmly onto the throttle body ports until fully seated. Reposition the spring clamps over the hose connections, ensuring they are located at least 1/4 inch from the hose ends.
9. 9

   Reconnect electrical connector and air intake
   Connect the throttle body electrical connector, ensuring it clicks into place and the lock tab engages. Reinstall the air intake duct to the throttle body inlet and tighten the clamp securely. Reconnect the mass airflow sensor electrical connector.
10. 10

    Reconnect battery and perform relearn procedure
    Reconnect the negative battery terminal. Turn the ignition to ON position without starting the engine for 30 seconds to allow the PCM to initialize. Connect the OBD-II scan tool and perform the throttle body relearn procedure according to the scan tool manufacturer's instructions. This typically involves running the engine through specific RPM ranges to allow the PCM to learn the new throttle position sensor parameters.

Reassembly

1. Reinstall engine cover by aligning grommets and pressing down firmly until seated
2. Check coolant level in overflow reservoir and top off if necessary with Motorcraft Orange Coolant
3. Clear any diagnostic trouble codes stored during the repair procedure

Verification

• Start the engine and verify smooth idle with no throttle-related diagnostic trouble codes
• Check for coolant leaks around the throttle body hose connections
• Test throttle response by gently increasing engine RPM - response should be immediate and smooth
• Perform a test drive to verify proper throttle operation under load and confirm no check engine light illumination
• Verify idle speed returns to normal (approximately 650-750 RPM in Park) after relearn procedure is complete

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