This procedure covers the replacement of the throttle position sensor on the 3.5L EcoBoost V6 engine, including proper removal, installation, and system relearning.

Warnings

Tools required

Parts

• Throttle Position Sensor × 1 — Use OEM Ford specification
• TPS mounting screws (if corroded) × 2 — Use OEM specification

Preparation

1. Ensure engine is completely cool
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 2 minutes for capacitor discharge
4. Remove engine cover by pulling upward on front edge, then lifting away
5. Locate throttle body on driver side of engine, mounted to intake manifold

Procedure

1. 1

   Access throttle body area
   Remove air intake duct from throttle body by loosening the hose clamp at the throttle body connection. Disconnect any electrical connectors on the intake duct, then remove the duct to provide clear access to the throttle body and TPS.
2. 2

   Disconnect TPS electrical connector
   Locate the throttle position sensor electrical connector on the side of the throttle body. Press down on the locking tab while pulling the connector straight away from the sensor. Do not twist or rock the connector excessively.
3. 3

   Remove TPS mounting screws
   Identify the two TPS mounting screws on the throttle body. These are typically small Torx or Phillips head screws. Carefully remove both screws and retain them if they are in good condition. Note the orientation of the sensor before removal.
4. 4

   Remove throttle position sensor
   Gently pull the TPS away from the throttle body. The sensor slides off the throttle shaft. If resistant, carefully wiggle while pulling straight out. Do not pry against the throttle body housing.
5. 5

   Clean mounting surface
   Inspect the throttle body mounting surface for debris, corrosion, or old gasket material. Clean the surface with electrical contact cleaner if needed. Ensure the throttle shaft rotates freely and smoothly without binding.
6. 6

   Install new TPS
   Align the new throttle position sensor with the throttle shaft, ensuring the sensor's drive tabs engage properly with the shaft flats. Slide the sensor onto the shaft until it seats flush against the throttle body mounting surface. Verify correct orientation by comparing to the removed sensor's position.
7. 7

   Install TPS mounting screws
   Install both TPS mounting screws and thread them in by hand initially. Tighten the screws in a crossing pattern using a torque wrench to the specified torque value. Do not overtighten as this can crack the sensor housing.
   Torque spec

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

   Reconnect electrical connector
   Reconnect the TPS electrical connector to the sensor, ensuring it clicks fully into place. Verify the locking tab engages properly. Gently tug on the connector to confirm it is secure.
9. 9

   Reinstall air intake duct
   Reinstall the air intake duct to the throttle body, ensuring proper seating. Tighten the hose clamp securely. Reconnect any electrical connectors that were disconnected from the intake duct.
10. 10

    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 PCM to initialize. Connect an OBD-II scanner and perform the throttle body relearn procedure according to the scan tool instructions. This ensures proper idle and throttle response.

Reassembly

1. Reinstall engine cover by aligning mounting grommets and pressing down firmly until seated
2. Perform power window auto-up/down relearn by holding each window switch up for 5 seconds after full close

Verification

• Start engine and verify smooth idle with no hunting or surging
• Rev engine slowly and verify smooth throttle response without hesitation
• Check for diagnostic trouble codes using OBD-II scanner; clear any codes related to TPS learning
• Test drive vehicle to verify normal acceleration and no check engine light
• Monitor short-term and long-term fuel trims to ensure they remain within normal range (-10% to +10%)

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