I didn't see a tutorial on how to remove that dead secondary shaft in the throttle bodies. Removing the plates is good, but the shaft is not as the ECU expects the servo to actuate the throttle position sensor.....a nice constant flashing error display will be the result. This mod removes the shaft, plugs the holes, and restores ECU operation by fitting the TPS directly to the servo with a modified shaft.
That's it. And it works! The only disadvantage is lack of a computer assisted high idle for cold weather starts.
I took pictures along the way:
This is after I removed the rod and plugged the holes with epoxy. You'll have to drop the engine to get fair access to the bodies, unbolt the two sections and slide the rod out. Discard the misc. hardware.
Here's how I checked to see what the ECU was looking for. Preloading the TPS on the servo shaft was all it needed. Fine, now let's see how to rig this up...
Here's what we have to work with. We will need to shorten the shaft...
A dremel tool works nicely to shorten and create a new flat keyway...
The shaft and pin slides neatly into the servo....
See how the TPS fits neatly into the servo? How convenient!
Ready for assembly...
sides of the shaft can be epoxied so it won't fall out of the servo
Finished installation. Be sure to test and retest the preloaded position before applying epoxy.
Testing.