How to convert your mustang 55mm throttle body to a 65mm explorer

[blazinchuck]

Im doing this swap now. I found another tech article on how to do this but there were a couple things that seemed like it could be done better. I wrote this up and jayt/chuzie hooked it up in a pdf for downloading(thanks guys).

this is for taking a explorer 65mm throttle body and adapting it to the mustang/explorer intakes and retaining the TPS and throttle cable connections. Hope this helps, lemme know if i missed something

How to convert your Mustang 55mm throttle body to a bigger
65mm Explorer throttle body
Before you can slap that explorer throttle body on, a few things need to be changed.
1. The throttle lever is indexed wrong and needs to be swapped with the one from the mustang.
2. The explorer TPS can be used, but the connector plug is wrong and must be changed out with mustang
connector.
3. The vent tube needs to be re-clocked to match angle of the tube on the mustang TB.
For the throttle lever, I used an angle grinder and ground the tip of the throttle shaft that holds the lever in place.
Grind it smooth and flat, then pry the lever off of the mustang TB. Both shafts are the same diameter, so the
lever assembly from the mustang will fit the explorer shaft perfectly.
[ATTACH=CONFIG]6742[/ATTACH][ATTACH=CONFIG]6743[/ATTACH][ATTACH=CONFIG]6744[/ATTACH]

Once the mustang lever is swapped over to the 65mm TB, I drilled and tapped the center of the shaft to secure
the lever. I used a drill size #29 and tapped it 8-32x3/8”. I used a drop of blue lock-tite and a washer.

[ATTACH=CONFIG]6745[/ATTACH][ATTACH=CONFIG]6746[/ATTACH][ATTACH=CONFIG]6747[/ATTACH]

As for the TPS, this is pretty simple. Both plug connectors are different in shape, but the pins are the same. I
removed the center lock in both connectors and then pulled the pins out from the back.
Once the center plastic lock is removed, there is a plastic “flag” securing the pins in their holes…I used a small
pick to pry then towards the center of connector. It doesn’t take much to pry it and pull the pin from the back
side-you don’t want to break any of this.

[ATTACH=CONFIG]6748[/ATTACH][ATTACH=CONFIG]6751[/ATTACH]

The colors are the same on the explorer TPS and mustang TPS.

[blazinchuck]

Here you can see the connector was removed from the explorer TPS wiring

[ATTACH=CONFIG]6752[/ATTACH]

Ready to reinstall pins from explorer TPS into this mustang connector.
[ATTACH=CONFIG]6753[/ATTACH][ATTACH=CONFIG]6754[/ATTACH][ATTACH=CONFIG]6755[/ATTACH]

Pins are in, and the center plastic lock is installed…now the TPS is done.

Now, for the vent line…my explorer TB came with a vent line, but it was pointing in the wrong direction. I
sprayed it with WD-40 and used pliers to turn it to match up to the mustang’s. I didn’t see a need to remove and
reinstall with epoxy. This was still very tight once I turned it. I’ve heard some models do not have a vent tube,
but there is a spot in the housing for it. If this is the case, you will need to twist and carefully remove the tube
from the mustang and measure it. Then drill the correct hole to insert the tube into the explorer housing. For this
you may want to use epoxy to lock it in.

[Kurth]

Im doing this swap now. I found another tech article on how to do this but there were a couple things that seemed like it could be done better. I wrote this up and jayt/chuzie hooked it up in a pdf for downloading(thanks guys).

this is for taking a explorer 65mm throttle body and adapting it to the mustang/explorer intakes and retaining the TPS and throttle cable connections. Hope this helps, lemme know if i missed something

I'm converting mine now. Thanks!