engine

Throttle Position Sensor

for 2007 Ram 3500 5.9L I6 Cummins · 4WD

Difficulty

Easy

Time

54 min

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure covers removal and replacement of the Throttle Position Sensor (TPS) on the 5.9L Cummins diesel engine, which monitors accelerator pedal position and sends signals to the ECM.

Warnings

⚠Disconnecting the battery will erase radio presets and require ECM relearn procedures after repair

ℹ️The TPS on the Cummins diesel is mounted on the intake horn/air inlet and monitors actual throttle valve position, not pedal position

⚠Do not force the TPS during installation as the internal potentiometer can be damaged

Tools required

8mm socket or wrenchEssential

Ratchet and extensionEssential

Flat blade screwdriver

Electrical contact cleaner

Torque wrench

OBD-II scan toolEssential

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Parts

Throttle Position Sensor × 1 — Use OEM Mopar or quality aftermarket (Bosch, Standard Motor Products)
Electrical connector sealing grease × 1 — Dielectric grease

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level surface and engage parking brake
Turn ignition to OFF position and remove key
Disconnect negative battery cable to prevent fault codes during sensor replacement
Allow engine to cool if recently operated
Retrieve and document any existing fault codes with scan tool before beginning work

Procedure

1
Access the throttle position sensor
Open the driver's door and locate the Accelerator Pedal Position Sensor (APPS) at the accelerator pedal assembly. On the 5.9L Cummins there is no throttle body on the intake; the pedal-mounted sensor reports driver input to the ECM. It is a black plastic sensor with an electrical connector.
2
Disconnect the electrical connector
Press the red locking tab on the TPS electrical connector and pull the connector straight off the sensor. Do not pull on the wires themselves. Inspect the connector terminals for corrosion or damage.
3
Remove the TPS mounting bolts
Remove the fasteners securing the accelerator pedal position sensor (APPS) to the pedal assembly per the factory service manual for this vehicle. Verify fastener size and count against the FSM before beginning, and keep hardware in a safe location for reinstallation.
4
Remove the old TPS
Carefully remove the accelerator pedal position sensor (APPS) from the pedal assembly, noting its orientation. Follow the FSM removal procedure; there is no throttle shaft on the Cummins diesel.
5
Inspect mounting surfaces
Inspect the accelerator pedal linkage and APPS mounting surface for damage or wear. Verify the pedal moves smoothly through its full travel without binding. Clean the mounting surface as needed.
6
Install the new TPS
Install the new accelerator pedal position sensor (APPS) onto the pedal assembly in its correct orientation per the FSM, ensuring it seats fully against its mounting surface.
7
Install mounting bolts
Thread the APPS mounting fasteners by hand first to prevent cross-threading, then tighten to the torque specified in the factory service manual for this vehicle. Do not overtighten plastic-backed sensor housings.
8
Reconnect electrical connector
Apply a small amount of dielectric grease to the sensor terminals. Push the electrical connector onto the TPS until it clicks into place. Verify the red locking tab is fully engaged and the connector cannot be pulled off without depressing the tab.
9
Reconnect battery and perform relearn
Reconnect the negative battery cable. Perform the accelerator pedal position sensor (APPS) idle validation/relearn procedure as specified in the factory service manual for this vehicle; a generic key-on self-test may not be sufficient.

Reassembly

Verify all electrical connections are secure and properly locked
Ensure no tools or parts were left in the engine bay
Double-check that mounting bolts are tight and the sensor is properly seated

Verification

Start the engine and verify it idles normally without hunting or surging
Use scan tool to verify TPS voltage reads approximately 0.5-0.9 volts at idle
Press accelerator pedal slowly and verify TPS voltage increases smoothly to approximately 4.5 volts at wide open throttle
Check for any new diagnostic trouble codes related to TPS circuit (P0122, P0123, P0223)
Perform a test drive to confirm normal throttle response and no warning lights
Clear any stored fault codes after verifying proper operation