DIY TPS sensor Fix...
 

Bad ones cause surging with auto's on the freeway, manual tranny's would also benifit from the cleaning but wont notice the affects. you MAY see a slight bump in mileage as the PCM wont think your foot is mashed to the floor intermitantly anymore (no noise).


4.7 motor in my Dak... had a bad surging problem on the freeway and as we all know it's the TPS. So having nothing to loose, I yanked it out, drilled a small hole large enough to fit a spray tube for a can of CRC electronic components cleaner and sprayed it in until I felt there was enough in there to clean it... I then turned the TPS shaft several times to clean the contacts on the inside. Dried it out, slapped it back in, took it for a drive and bam... no more surging. rock solid on the freeway now.

SO now we have a fix for the TPS sensor. This will work for the 3.9/5.2/5.9/4.7 motors and probably the 3.7 & 5.7 motors as well.

When your done, put a very small piece of electrical tape over the hole and then cover the tape with silicon to keep the tape in place and to keep dirt out. I dont suggest filling the hole with silicon as if you need to access the hole again, you may push some that is in the hole into the sensor which could cause problems.

1. Remove TPS sensor from Throttle body. the 4.7's take a T20 torx bit/driver to remove the screws.

http://i41.photobucket.com/albums/e2...S001Medium.jpg
http://i41.photobucket.com/albums/e2...S002Medium.jpg


2. Drill a 1/8" hole in a spot where you will be able to spray in CRC Electronic Component Cleaner and the drill bit will not go in too deep too fast.
in other words... drill with a very light hand so you dont damage the contents of the sensor.

http://i41.photobucket.com/albums/e2...S004Medium.jpg

3. Spray the cleaner into the hole, dont be shy with it...

http://i41.photobucket.com/albums/e2...S003Medium.jpg

4. Rotate the sensor shaft so that the cleaner will get into the contact area's of the sensor.

5. Shake out the excess solvent until all of it is out.

6. Once your convinced it is dry, cover the hole with a very small piece of electrical tape and seal with silicon sealant. I used clear so I can see the tape when it dries, probably wont be necessary to have clear. If you dont use tape, you could get sealant into the TPS and that may cause problems that you cant fix w/o buying a new one.

http://i41.photobucket.com/albums/e2...S005Medium.jpg

http://i41.photobucket.com/albums/e2...S006Medium.jpg
7. reinstall sensor into the TB.

8. Reconnect the sensor electrical connector and your done.

RE: DIY TPS sensor Fix...
 

Sounds like a good fix. But actually drilling a hole in a TPS isn't a great fix. Not to mention most people have a lot to loose. But to drill a hole into something that others aren't too sure of is mad in my opinion. I think just removing it and fully cleaning it could break it loose or simply replacing it would work. I like your thinking about this subject but how much money is this going to save?
I'm not dissing the idea, but if you are going to bring this up I think some pictures are in store.

RE: DIY TPS sensor Fix...
 

if your going to swap it out anyway, what do you have to loose? It's well known that the noisey tps will cause surging in AT equipped trucks & suv's so if this will fix it, all the better.

If anyone is uncomfortable drilling a small hole in thier TPS... they can always go buy a new one.

RE: DIY TPS sensor Fix...
 

the part is sealed... you cant spray it and expect any better results. That's why you have to drill a hole to allow the solvent to get into the sensor and onto the contacts.

RE: DIY TPS sensor Fix...
 

Like I said I'm not dissing it. You are right by tring to clean it.

But again HOW do you go about doing so?
Where do you drill?
How much contact cleaner do you use?

Lets see some pics so that everyone can do this. These are some cheezy instructions full ofquestions.

RE: DIY TPS sensor Fix...
 

I guess when I put out detailed DIY writeups, your comments make sense... there isnt much to it though. I have updated the instructions at the top and will add pics this weekend...

RE: DIY TPS sensor Fix...
 

Thanks dude. I'm sure this can be a great fix.