Engine/Transmission (1994 - 1998) New Throttle Position Sensor; Question, 1996 12v auto trans

[Solar1]

Hello Folks.
I've read several TPS threads trying to get info pertaining to my issue.
Here we go:

Just had new auto transmission installed.
I was having some issues with overdrive; it seemed to stay in lockup even when going upgrade.

Took it in trans shop.
They say they got a code referring to the TPS and it needed replacement.
I picked a new one up and installed it. (over the years, I've installed two previously with no issues)

I cannot get the 1 volt reading without major adjustment of the linkage rod.
I know the 126mm adjustment is critical. I need to adjust it to about 122.5mm to get the 1 volt reading (+/- .2)
I did not want to run the truck at that linkage setting so I put it back to factory service manual setting (126.5mm)

Could it be that a brand new unit is bad out of the box?
I have yet to check my voltmeter for accuracy.

One thought is that there may be too much play in the shaft/spring assembly that the TPS bolts onto.
There seems to be some slop.
I did preload the sensor while installing.

I read a thread here discussing a battery disconnect and throttle sweep procedure. (for the computer to "learn?)
Would that procedure apply to my truck?

Any ideas would be appreciated.
Thanks

 

[Bob4x4]

A 96 will have significant wear. There are 2 bushings that protect the pivot on the linkage. I will bet also that the key that fits into the sensor is at least worn to half of its original size

 

[Solar1]

Thanks Bob4x4,

Would you happen to know if those parts are available individually, or are they sold as an assembly?
Cummins only as parts source?
Thanks

 

[Bob4x4]

Cummins and Ram dealers should both have the bushings available.They both also have a kit but not much of the kit works on the pick-ups or is a good value,i have welded up the worn parts and machined back to the correct size.mike wilson can probably put up a parts diagram

 

[GAmes]

It is irritating that the pictures were dumped from the old threads. https://www.turbodieselregister.com/threads/236195-attn-high-milers-throttle-linkage-repair The video still works.

 

[Solar1]

Thanks for the video link...EXCELLENT!
If someone (maybe mwilson ???) is reading this and can help with a part number, I would appreciate it greatly.
I may need the plate/shaft part that the spring mounts onto.
My engine number is 56257772
I was able to get the bushing part number from the video (4425053)
THANKS!

 

[Solar1]

Just to let folks know I ordered and replaced the bushings. I fixed the issue. I did find the there is also a little wear on the key shaft as suggested. For to time being, I slotted out the TPS sensor bracket just a bit to give me the extra adjustment I needed to bring the TPS reading up to 1 volt. Down the line I will need to replace that shaft assembly.
Thanks all for the help!