This procedure replaces the throttle position sensor (TPS) on the 3.5L EcoBoost V6 engine, which monitors throttle plate position and sends data to the PCM for fuel and ignition control.

Warnings

Tools required

Parts

• Throttle Position Sensor (TPS) × 1 — Motorcraft DY-1390 or equivalent OEM

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely for at least 30 minutes
3. Disconnect negative battery terminal and wait 2 minutes to allow capacitor discharge
4. Remove engine cover by pulling upward on four retention clips

Procedure

1. 1

   Access throttle body area
   Locate the throttle body on the driver side of the intake manifold. Remove the air intake duct by loosening the hose clamp at the throttle body inlet using a 10mm socket. Disconnect the fresh air tube by pressing the release tab and pulling upward. Set the air intake duct aside to provide clear access to the throttle body.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the throttle body assembly. Press down on the red or gray locking tab while pulling the connector straight away from the throttle body. Do not twist or rock the connector. Inspect the connector pins for corrosion or damage.
3. 3

   Document sensor orientation
   Before removing the TPS, note the orientation of the sensor relative to the throttle body. The sensor has a specific rotational alignment that must be maintained. Take a photo if necessary to ensure correct reinstallation.
4. 4

   Remove TPS mounting screws
   Using the T20 Torx bit, carefully remove the two TPS mounting screws. These screws are very small and easily stripped. Apply steady downward pressure while turning counterclockwise. Keep screws in a safe location as they are usually not included with replacement sensors.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
5. 5

   Remove TPS from throttle body
   Gently pull the TPS straight out from the throttle body shaft. Do not rotate or twist the sensor during removal as this may damage the throttle shaft. If the sensor is stuck, do not pry on it. Instead, gently wiggle it side to side while pulling outward.
6. 6

   Inspect mounting surface
   Examine the throttle body mounting surface and shaft for any damage, debris, or corrosion. If an O-ring seal is present on the old sensor, ensure it is removed and the mounting area is clean. Wipe the area with a clean shop towel. Do not use solvents on the throttle plate or bore.
7. 7

   Prepare new TPS
   Remove the new TPS from packaging and verify it matches the old sensor. Check that any O-ring seals are properly seated on the new sensor. Apply a small amount of dielectric grease to the electrical connector terminals on the new sensor to prevent corrosion.
8. 8

   Install new TPS
   Align the new TPS with the throttle shaft, ensuring the sensor body matches the orientation noted during removal. The sensor will only install in one position. Gently push the sensor onto the shaft until it seats flush against the throttle body mounting surface. Do not force it.
9. 9

   Install and torque TPS screws
   Insert both TPS mounting screws and hand-tighten them in a cross pattern. Using the torque wrench with T20 Torx bit, torque both screws to specification in a cross pattern to ensure even pressure distribution. These screws require very low torque, so use caution.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
10. 10

    Reconnect electrical connector
    Align the electrical connector with the TPS terminals and push firmly until you hear and feel a distinct click. Verify the locking tab is fully engaged. Gently tug on the connector to confirm it is secure.
11. 11

    Reinstall air intake components
    Reconnect the fresh air tube to the air box by pushing down until it clicks into place. Position the air intake duct over the throttle body inlet and secure with the hose clamp, tightening the 10mm bolt until snug but not over-tightened.
12. 12

    Reconnect battery and initialize
    Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine. Wait 30 seconds to allow the PCM to initialize and recognize the new TPS. The throttle plate will perform a self-calibration sweep. Do not touch the accelerator pedal during this process.

Reassembly

1. Reinstall engine cover by aligning clips and pressing down until all four clips snap into place
2. Verify all electrical connectors are properly secured and no tools were left in engine bay
3. Ensure air intake system is completely sealed with no loose clamps or disconnected hoses

Verification

• Start the engine and verify it idles smoothly without hesitation or surging
• Check for diagnostic trouble codes using an OBD-II scanner; clear any stored codes related to the old sensor
• Test drive the vehicle and confirm smooth throttle response during acceleration and deceleration
• Verify no air leaks are present at the throttle body inlet connection
• Monitor for check engine light illumination over the next several drive cycles

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