1995 E350 7.3 Powerstroke
My check engine light is on, throttle pedal sometimes responds to pressing it - sometimes not, transmission shifts hard. I've had the truck checked by two mechanics who say it needs a new throttle pedal. However Ford says they are no longer available. I've read this on other forums.

Has anyone come up with a replacement?
John

 

I think that a junk yard is your only option, or some one that has a donor vehicle. Here is a bump for more input.

 

Soak the ivs with contact cleaner and blow it out with air.
You can get a aftermarket tps (Dorman 699-200) but be ready to change them every 6-8 months

 

Thanks, guys. Unfortunately the Dorman site shows the 699-200 as not fitting my vehicle. The photo doesn't look like my sensor. This is very frustrating.

 

This is not mine, but I have it saved in my PC, maybe helps you:

TPS easy fix.

I recently had some very strange problems CEL light related to my TPS pedal assembly which is only 4 mos old. Nasty shifts, CEL as soon as I turned the key. Replaced the VSS WD40 the TPS and nothing helped. Here is what I found very strange findings. Really started ticking me off. Anyways here is what i found. There is a bras shaft that is splined that moves the TPS. Well once this gets wore in a little it tends to get some side to side play...this in turn was altering the movement of the TPS. the shaft would slide to the right and id get CEl all the time. I found out just today that if i push the rod back in tight that the CEL would go off, but i few pushes of the pedal and it would work loose again. I pulled off the pedal assembly and saw that when it was slid out it must have let the TPS go below the right position throwing a CEL. All I had to do was slide it in tight and in the gap between the spring ad plastic keepers that hold the rod in I simply took a piece of bailin wire and put it around the rod and twisted it at the top then snipped of the extra. This filled the gap which in turn took all the play out of it, holding the rod tightly in place. Guess what no more problems im happier than hell and very relieved. So if u guys suspect something of this nature check this out.

 

There is a different part listed for 1994-1995 trucks (F5TZ9F836A) than for 1996-1997 trucks (F6TZ9F836AA). The 1996-1997 part is MUCH cheaper

I think this # part F5TF 9F832 is for the APP (accelerator pedal position sensor) but dont quote on that.

 

I had the problem with the CEL after doing a e40d-zf swap. Throwing a CEL and absolutely no throttle response. It ended up being that part described above in the TPS that has play it in, and it had slid too far to one side and was throwing a code...can't remember the code number, but i believe it was something like "Throttle Position Input - Out of Range".

Since these trucks are "drive-by-wire" and have no throttle cable, the TPS varies the voltage that it sends to the PCM as you push the pedal down - so the farther you push down, the higher the voltage that is sent to the PCM, and more fuel is put to the engine. When that piece slipped off to the side, the voltage dropped below what it is at idle and the CEL came on because the voltage was "out of range". Once we fixed that piece that was sliding, it was good to go and no CEL.

Don't know if that's your problem, but it would be worth checking. I can't imagine you needing a new pedal...unless there was some trauma to it. It's got to be a sensor, I would think.

 

Oh, and if you have a meter, you can take your throttle position sensor out and do some tests to see if it is actually working before you go buy a new one. That's what Bill and I did, then he saw that the piece was slid off to the side and had disengaged from the pedal assembly. Turns out my TPS was working just fine.