Engine/Transmission (1994 - 1998) How To Install TPS Without Breaking It?

[RHestand]

I don't think I've ever been quite this frustrated!

My just rebuilt trans. has not been shifting like it should when hauling heavy, so I decided to pull my throttle position sensor (TPS) and check it with my volt meter, following the directions I read here on TDR. After doing all the tests, it checked out fine, so I reinstalled it and broke it. (The internals popped out. ) Not knowing what I did wrong, (I thought maybe it was old and already cracked or something?) so I just ordered another one from Rock Auto.

It arrived today so I installed it and again pushed the guts out of the new one!!

What am I doing wrong? I'm aligning the male blade on the engine with the female slot in the TPS, while holding the TPS in place and starting and snugging the two long screws that hold the TPS to the linkage.

I'm thinking maybe there are some spacer tubes missing, that the long screws go into, so the TPS can be snugged up to the linkage without pushing the guts out of it. I don't know what I'm doing wrong, but I sure don't want to break another one ($110 ea. ).

Can anyone get me going in the right direction as to what I'm doing wrong? Pictures? Advice?

I'll be ordering another one in the morning so any and all directions will be much appreciated.

TIA, Ray

PS- I tried pulling this up on the Search Forum, but as usual, I can't get anything to come up.

 

[budnate]

you do have to index the tps with the blade in the throttle housing but it should just pop in if you have the screws aligned with the holes... you do have that goofy metal bracket that goes in between the tps and the housing right? it holds the tps wiring harness... . anyway it should just go on and lay flush while you install the screws, no binding or force needed, sounds like something is rotated wrong, grab a mirror and look at the throttle blade that rotates the tps, something in there may be not right.



I am headed out the door, I am sure someone has a picture to post of one installed if not I will grab one for you tonight.



if you hogged out the holes on the tps to gain initial voltage setup it can be tricky to get it in right, I gently push in until i feel it engage and then rotate it back and forth and feel it load up the tps spring a few times then come back to center and install the screws one at a time, it can be a pita that's for sure at times I have had mine on/off so many times its pretty easy now.

 

[RHestand]

you do have to index the tps with the blade in the throttle housing but it should just pop in if you have the screws aligned with the holes... you do have that goofy metal bracket that goes in between the tps and the housing right? it holds the tps wiring harness... . anyway it should just go on and lay flush while you install the screws, no binding or force needed, sounds like something is rotated wrong, grab a mirror and look at the throttle blade that rotates the tps, something in there may be not right.

I am headed out the door, I am sure someone has a picture to post of one installed if not I will grab one for you tonight.

if you hogged out the holes on the tps to gain initial voltage setup it can be tricky to get it in right, I gently push in until i feel it engage and then rotate it back and forth and feel it load up the tps spring a few times then come back to center and install the screws one at a time, it can be a pita that's for sure at times I have had mine on/off so many times its pretty easy now.

Thanks budnate, I appreciate your response.
I checked out that blade this morning and it looks good. When I get my new one I'll try your technique about rotating it in both directions after getting the blade inserted. It's such a PITA to get both hands/arms in there, even after pulling the charge-air pipe off.
The good news is I called Rock Auto this morning to order another TPS and after the sales guy noticed I had just bought one he transferred me to customer service and they said it would be covered by their 30 day warranty?? I told him what happened and he said it was probably defective, so I was not going to argue about it.
I do know this, I think it was very generous for Rock Auto to volunteer a replacement part, especially an electrical part and I'll not be forgetting that soon.
My part probably won't be here till Monday so if you guys have some more ideas or links for me to look at, please pass them on.
TIA, Ray

 

[Bob4x4]

If it broke after use inspect that your linkage does not have excessive wear. If it broke during the instal be more careful next time. Do not over torque especially if the aftermarket version does not have metal sleeves

 

[WilsonF]

You might try this, it's only about $40

http://www.dieselbombers.com/5-9l-rotary-performance/73413-installed-dnr-tps-delete.html

 

[RHestand]

WilsonF, Thanks for that link. I only wish I had known about this earlier. If this new TPS doesn't get the trans shifting properly I will definitely try one of these.
The problem I'm having with my recently rebuilt trans is, when towing heavy with the shifter in Drive and accelerating up to highway speed , it will often shift into O. D. /lock-up at the same time. This too early shift drops the eng. RPM too quickly, makes the turbo bark and then the acceleration is sluggish.
What do you guys think about this problem, am I looking in the right spot (TPS)? Any ideas on this? Is both O. D. and lock-up controlled electronically?
TIA,Ray

 

[S.Morris]

The DNR works really well. We went through several on a very high mileage97. The aftermarket ones (napa) didn't last long enough to bother putting on. The OEM was better but 6months or so. Installed the DNR in its place and was still in use two years later when the truck was retired from extreme body rot with 970000 on it.

 

[JMcCoy]

The potentiometer is the way to go. I also have an ATS shift Commander that allows me to adjust when the converter locks up. It is awesome. You can install it on anyone's 47re. I'm not sure if other companies make a similar controller or not. I can now control when I go into OD and when I lock up the converter. I usually have it set to lock up, then shift into OD arround 50 mph + or -. Good luck, let us know how it works out.