Joined: 05 Feb 2008, 19:52 Posts: 217 Location: Chattavegas tennessee...
60-75mm Sn95 throttle body install on stock intake
First I will say this isnt a mod for a starter.And is probly a waste of both time and effort below 300 h/p.
Step 1 Obtain a 94-95 5.0 mustang thottle body or super coupe unit and a upper intake gasket set for the year car you are working on. (note some aftermarket units require more work to install) and a 3" to 2.5 silicone reducer for 87-88's
Step 2 Remove your exsisting upper intake and throttle body assembly dissasemble the throttle body from the intake and clean and paint parts as desired.
Step 3 Use the stock 5.0 gasket to mark the opening needed in the upper intake you will need to open this area with a grinding bit and will take a bit of work and time sometimes you may have to taper the area due to lack of material or have it welded.
Step 4 Now with your intake prepared you will be ready to mock up the TB.What you will want to do is remove the inner (firewall side) lower stud from the throttle body mounting flange on the intake the 2 outer holes should line up with your factory intake holes if they do not you will have to enlarge the holes a little bit until there is exceptable clearances usually a 3/8 bit will work to do this.After you get the outer holes to align you will be ready to mark the inner holes wich will have to be redrilled into the throttle body I always use a thin sharpie to mark the location of the holes going from the backside of the intake mounting holes.After you marke the holes you will need to center punch them so you can drill the holes.Use the same 3/8 bit to drill these.
Step 5 You should have the holes redrilled by now and it "should" bolt onto the mounting flange verify this.If it fits you are now ready to check 2 things. 1.that it fits. and 2.that the IAC "slot" doesnt protrude past the thorttle body mounting flange.IF this "slot" protrudes past the flange you will need to construct a metal shim to go between the body and intake this can be done with so metal at least the thickness of an old liscence tag.You will want to make this plate to match the demesions of your throttle body and NOT the intake.
Step 6 I like to use permetex import grey to seal the plate to the intake and then plate to gasket use a good throttle body gasket on the opposing side without sealer.
Step 7 You will need a 94-95 TPS and pigtail and a Good IAC Set the tps volts to .95-.99 by slotting the mounting hole if needed
Step 8 Install upper intake use a new gasket to mount. rest of installation is reverse of removal.
Step 9 You may notice that the intake will not seat due to the factory oil seperator i cured this by making a dimple in my factory one for the IAC.there may be other avenues
Step 10 Throttle cable you will need to move the front mounting hole back into the rear mounting hole.this will move the calbe bracket away from the throttle body and make it exceptable for use make sure to screw the front bolt back in and snug it down.You may have to do some minor bending or grinding to the thorttle bodies arm.
Step 11 You should be ready to fire it off. do any minor adjustments as needed.
Step 12 Enjoy you new found throttle responce!
_________________ Thank God I'm a Hillbilly and not an import worshipping communist.
30 Mar 2008, 10:04
TurboLX
ADMINISTRATOR
Joined: 29 Jan 2008, 20:12 Posts: 380 Location: New York
Re: 60-75mm Sn95 throttle body install on stock intake
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