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I've seen a lot of posts about rough idles and stalling, and my 91 5.0 is no different. since i had a code for tps low voltage i thought i'd start by replacing that first and seeing if it fixed the problem. the casing on my tps wires was stripped and all of the wires were touching, so its a good chance that even if it doesn't solve the problem, it needs to be replaced anyway.
the question i had was how do you get the darn thing off without removing the throttle body? if that is what you have to do to remove it, how do you adjust the new one you put on? I thought you had to adjust it with the engine running?
You don't have to remove the throttle body to get to it, and before you replace it I would suggest just cleaning the hell out of it. If it's not SUPER dirty (which causes it to stick and cause the problems) then you might want to try spraying some cleaner into the throttle body while holding the engine rpm's high enough to not stall out. If it still sticks after that, just take it out of the side of the throttle body (which doesnt have to be removed) and you'll see the huge access to the slide, and probably a lot of garbage built up on it. use the parts cleaner of your choice and clean it then reinstall. If all cleaning attempts fail, then buy a new one but try to clean it first.
I haven't found any way to replace it without removing the throttle body. Here's what you do to adjust it before you put the throttle body back on:
-hook up a voltmeter between the green and black wires
-turn the key to "on"
-rotate the TPS around until the voltmeter reads 0.99V or less (I set mine to 0.95V because my throttle body doesn't always go back to the same rest position)
-tighen the screws down
After you tighten the screws down, snap the throttle open and closed by hand a few times to make sure that it doesn't read above 0.99V ever. If it does, back it off a little.
I tried to take mine off with one of those '90 deg' screw-driver-flat-head things, and the two screws come out to the point that they hit the lower intake manifold. I have no idea how you can't avoid taking it off.