How To Port, Polish and Half Shaft your Throttle body.

Parts needed
1 - 60 grit 3" paddle sanding wheel $5
1 - 120 grit 3" paddle sanding wheel $5
Vise
3/8" ratchet w/ 10MM socket
Hacksaw
#2 Phillips screwdriver
Flathead screwdriver
small flat file
Low or high speed Electric Drill
Red Loctite $5

Steps (TB = Throttle Body)

1. Use flathead screwdriver and remove the intake from the TB.
2. disconnect your throttle cable and/or cruise control cable and unplug your TPS sensor wires from TB.
3. Using 10mm socket unbolt the 4 main bolts that hold the TB on.
4. remove the TB; If it is stuck just give it a good tap with a hammer and it'll break loose
5. place TB in a vise with inlet side facing up
6. using 60grit wheel on electric drill slowly turn the wheel while carefully using your hands to clamp down on the wheel compressing it enough to force it into the inlet of the TB
7. once wheel is inside TB... GO CRAZY... PORT alot!
8. being careful not to hit the throttle plate you want to really port that ridge in front of the plate good!
9. after you feel you've done a sufficient job... proceed to the 120grit sanding wheel and do enough to polish smooth
10. turn the TB over and do the outlet side. Harder to do, but do as much as you can w/ both 60/120 grit

Half-Shafting
11. use the #2 phillips and remove the 2 Thottle plate screws
12. remove plate completely and carefully remove shaft. It slides out the spring end.
13. Use a hacksaw and cut both sides of the shaft on the side where the holes are NON-THREADED
14. goal here is to make flush with center slit of shaft.
15. use a file and round the edges to prevent damaging the bearings inside the TB

16. While TB is dis-assembled use 120grit sanding wheel and do a quick 2 to 3 passes all the way through (not too much)
17. slide the shaft back into TB and manipulate spring to hold it's original tension
18. put some loctite on the 2 screws which hold the thottle plate on the shaft and re-assemble the Throttle Plate
19. use the file to file down the back of 2 throttle plate screws leaving just 1-2 threads exposed above the shaft
20. Now that all is back together... wash the TB with some soap on water removing all metal dust
21. Dry completely, bolt back on intake w/ 10mm socket
22. re-connect your throttle linkage and tps sensor
23. clamp your intake back onto the throttle body and your done!!!

You shouldn't damage the gasket at all, but if your warry.. you can buy a new one from ford for $12.95. This mod should take an average person between 30 minutes to 1 hour at max and costs between $15 - $30 depending on if you want a new gasket or not... it's not required unless yours breaks apart.

Gains: 3-6BHP above 4,000rpms. Most noticable in passing situations. A great bang for the buck @ ~$3 Per HP

Anyone in the houston area... I have alot of experience with this and can do this for anyone. all they need to do is bring the two sanding wheels and/or gasket. I have everything else. Anything I can do to help fellow 4.2 owners.

 

Awesome post, man!

I have done this mod several times on other vehicles, and I agree with you. . .it's one worth doing on these, too.


Later,

 

Hey Thanks a lot Talley! Great post with easy to understand directions. I have your post printed out and once I get the supplies I'll do it. Just one question, what exactly does half-shafting do for it? I wouldn't think cutting the shaft in half would change very much. Doesn't it just make the throttle door a little lighter? Thanks again!

 

It will flow more... the shaft sticks up on the top of the TB about 4mm. removing this increases flow by 15-20cfm as documented on a 3.8L mustange TB which is 55mm. Ours is a 60mm.

 

hey Thanks! How do you ensure an even cut on the shaft with a hacksaw? I don't wanna break or cut the shaft unevenly, so what do you recommend?

 

You'll see what i'm talking about when you get there Just a straight verticle cut up from the edge of the middle slit in the shaft.

 

TTT.... Great info here, needs more attention.