This procedure covers the removal and replacement of the throttle body on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including disconnection of electrical and air intake components.

Warnings

Tools required

Parts

• Throttle body gasket × 1 — Use OEM specification
• Throttle body assembly (if faulty) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key
3. Allow engine to cool completely (minimum 2 hours after operation)
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal to prevent accidental throttle body electrical activation

Procedure

1. 1

   Remove engine cover
   Grasp the engine cover firmly at the front corners and pull upward to disengage the rubber grommets from the mounting posts. The cover is not bolted and should lift free with moderate upward force. Set the cover aside in a clean area.
2. 2

   Disconnect mass air flow sensor
   Locate the mass air flow (MAF) sensor on the air intake tube near the air filter housing. Press the locking tab on the electrical connector and pull the connector straight off the sensor. Do not pull on the wiring harness.
3. 3

   Loosen air intake tube clamps
   Locate the hose clamps at both ends of the air intake tube: one at the air filter housing and one at the throttle body inlet. Use a flathead screwdriver or hose clamp pliers to loosen both clamps. Do not remove clamps completely at this time.
4. 4

   Remove air intake tube
   Twist the air intake tube gently to break the seal at both connections, then pull the tube away from the throttle body and air filter housing. Remove the tube from the engine bay. Inspect the tube for cracks or damage.
5. 5

   Disconnect throttle body electrical connector
   Locate the electrical connector on the driver's side of the throttle body. Press down on the locking tab (usually red or gray) while pulling the connector straight away from the throttle body. If the connector is tight, gently wiggle it side to side while pulling.
6. 6

   Remove throttle body mounting bolts
   Locate the four throttle body mounting bolts around the perimeter of the throttle body flange. Using a 10mm socket, remove all four bolts in a crisscross pattern. Keep bolts organized for reinstallation. Note the bolt locations as some may be different lengths.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
7. 7

   Remove throttle body assembly
   Carefully pull the throttle body straight away from the intake manifold. The gasket may stick to either the throttle body or manifold surface. Do not allow debris to fall into the open intake manifold. Cover the manifold opening with a clean lint-free rag immediately after throttle body removal.
   ⚠Do not allow any foreign objects or debris to enter the intake manifold opening, as this can cause severe engine damage.
8. 8

   Remove old gasket and clean surfaces
   Remove the old throttle body gasket from both the throttle body flange and intake manifold mating surface. Use a plastic gasket scraper to carefully remove all gasket material without scratching the aluminum surfaces. Wipe both surfaces clean with a lint-free rag. Inspect for damage, warping, or deep scratches.
   ⚠Use only plastic scrapers on aluminum surfaces. Metal scrapers can cause scratches that lead to vacuum leaks.
9. 9

   Inspect and clean throttle body (optional)
   If reusing the throttle body, inspect the throttle plate and bore for carbon buildup. Spray throttle body cleaner onto a clean rag and wipe the bore and throttle plate. Do not spray cleaner directly onto electrical components or forcefully move the throttle plate, as this can damage the electronic position sensor.
10. 10

    Install new gasket
    Position the new throttle body gasket onto the intake manifold flange, ensuring all bolt holes align properly. The gasket should fit snugly without forcing. Remove the protective rag from the intake manifold opening just before installation.
11. 11

    Install throttle body
    Align the throttle body with the gasket and intake manifold flange, ensuring the electrical connector position faces the correct direction (driver's side). Press the throttle body gently against the gasket and hand-thread all four mounting bolts to prevent cross-threading.
12. 12

    Torque throttle body bolts
    Using a torque wrench, tighten the four throttle body mounting bolts in a crisscross pattern to 10 Nm (7 lb-ft). Start with the top bolts, then bottom bolts, then repeat the pattern to ensure even seating. Do not overtighten, as this can warp the throttle body flange.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
13. 13

    Reconnect throttle body electrical connector
    Align the throttle body electrical connector and push it firmly onto the throttle body until you hear and feel a positive click. Gently tug on the connector to verify it is fully seated and locked.
14. 14

    Reinstall air intake tube
    Position the air intake tube onto the throttle body inlet first, then connect the opposite end to the air filter housing. Ensure both connections are fully seated. Tighten the hose clamps to 4.0 Nm (3 lb-ft) using a torque wrench or snug by hand with a screwdriver.
    Torque spec

    Air Intake Hose Clamps3 Nm (2 lb-ft)
15. 15

    Reconnect MAF sensor and install engine cover
    Reconnect the mass air flow sensor electrical connector until it clicks into place. Position the engine cover over the mounting posts and press down firmly at each grommet location until the cover seats properly.
16. 16

    Reconnect battery and perform relearn
    Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine for 30 seconds to allow the throttle body to perform its self-calibration sequence. Do not press the accelerator pedal during this time.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm air intake tube clamps are tight with no air leaks
3. Ensure engine cover is properly seated on all mounting grommets
4. Double-check that no tools or rags were left in the engine bay

Verification

• Start the engine and allow it to idle. Listen for any hissing sounds indicating a vacuum leak at the throttle body gasket
• Verify idle is smooth and stable after the engine reaches operating temperature (may take 2-3 minutes)
• Rev the engine gently to 2000-3000 RPM and confirm throttle response is immediate with no hesitation
• Check for diagnostic trouble codes using an OBD-II scanner, particularly codes related to throttle position or airflow
• Test drive the vehicle to confirm normal acceleration and no check engine light illumination

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