On all 4.2L V6 and 2004 4.6L and 5.4L V8 models, the TP sensor is not replaceable; if replacement is necessary the whole electronic throttle body assembly must be replaced, which involves a new TP sensor. In 4.6L and 5.4L V8 model years 2005 and 2006 as well as 2005 through 2008, if the TP sensor is replaced it needs to be replaced with a new one since the manufacturer does not permit the reuse of the part. First of all, it is required to remove the negative battery terminal as well as the electrical connector of the TP sensor and to slide the red lock and press the release button. Take out the TP sensor mounting screws gradually but securely, and should use only high-speed power driver after tightening by hand in order not to break the mounting screws. Be very keen when fitting the new TP sensor such that the flat tip of the throttle plate shaft fits very well in the recessed area. Photo Description Installation procedure is done in a manner opposite to that of the removal process which involve using new sensor mounting screws tightened by hand until they are tight. For 2009 and later 5.4L V8, on TP sensor mounting screws, do not use power tool for removing the mounting screws, heat must be applied using 1100 watts heat gun while monitoring the temperature before it reaches about 130 degree F for removal by hand tool. The installation procedure is the same as in previous models as are new TP sensor fasteners. On 3.5L and 3.7L V6 and 5.0L and 6.2L V6 models, the TP sensor is located internally within the electronic throttle body assembly and cannot be repaired; replacement of the sensor requires replacement of the entire throttle body.
