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Discussion Starter #1 (Edited)
Pulled the throttle body today in order to clean it up and set the plate angle correctly and found what I'd call issues, but don't really have the expertise to know if they're that bad or not and what I can do to rectify it... Beyond cleaning up the liquid crud in the bottom of the intake manifold which appears to be have the color of old oil and the smell of diluted fuel (I can only assume the previous owner cleaned the TB without removing it and have no idea what was used...) the main thing I'm looking at with the TB is the plate shaft appears to not be pressed in quite far enough with daylight on TPS side and rub marks on spring side. I assume the plate should sit level but mine sits at a slight angle with adjustment screw all the way out. I also assume the plate should seal better (airtight or close to it with no rubbing). Before I totally de-clock this spring and make matters worse, all comments/suggestions to anything you see in the pics are welcome! [cheers]

Edit in: Should the TPS have an o-ring around the interface that inserts into the TB? In my research Motorcraft replacements have one but none of the aftermarkets do (which is what I have installed).
 

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Worried about the wrong thing. EVERY TB in the universe is slightly angled, if straight they would stick when you attempt to open them. The wear on one end is inconsequencial. DON'T reuse the gasket or more trouble coming up. You absolutely messed up by moving the screw. The stuff in bottom of intake does absolutely NOTHING to engine performance. ALL TPS have a seal but most people return them with the seal lost (or stolen).
 

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Discussion Starter #3
Worried about the wrong thing. EVERY TB in the universe is slightly angled, if straight they would stick when you attempt to open them. The wear on one end is inconsequencial. DON'T reuse the gasket or more trouble coming up. You absolutely messed up by moving the screw. The stuff in bottom of intake does absolutely NOTHING to engine performance. ALL TPS have a seal but most people return them with the seal lost (or stolen).
Ok, I need to find a TPS o-ring. The previous owner installed it without one and the one he removed didn't have one either. The TB gasket was destroyed upon removal and I have plenty of stock to make another. The plate adjustment screw was previously moved and I've studied up on the realignment procedure thanks in part to one of your replies in another thread. [thumb] So is it safe to say the daylight gap on the throttle plate at the TPS end is also inconsequential?
 

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X2, I run them like that all day long.

You CANNOT use flat say fiber or paper gasket under the TB (you can try of course but likely the IAC bypass port will blow out soon due to fuel exposure, and a vacuum leak), the seal does not work that way. To do so you would have to remove the slight stands under the corners of TB and guarantee the whole flat gets dead flat, and then you have another issue. The parts being plastic will tend to deflect to leak even if flat when you tighten them, they were only intended to slightly tighten and using a oldschool higher torque factor to properly crush the paper gasket will crack both. The molded in metal torque rings around bolt holes tend to break out of the plastic used like that. The proper silicone o-ring that goes there is overly thick to seal correctly across the daylight gap, and intended to seal correctly with only ounces of torque used there.

I myself filed the stands down flat to increase crush on the silicone o-ring there with the same torque (low).
 

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Discussion Starter #6
...Turns out it was all for naught...
I got home yesterday from dropping my daughter off at school (and purchasing the proper TB gasket) to find that the huge red oak which overhangs part of the driveway decided to let go of a branch (a little over a foot wide) which quickly ended any further maintenance projects on this car.[nutkick]
 

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Discussion Starter #9
Given I only paid $800 for it, I've yet to check compression and drop-down leak test, bogged down and threw a cylinder 2 misfire code w/flashing CEL the one and only time I've had it up to a decent speed (not while at idle or revving when parked), how these motors like to drop valve seats, it needed a complete 4-way brake job with new fluid, an oil leak (probably at the pan seal), new motor mounts, headlights only worked on high beams, needed an A/C fan motor (squalled like a kicked dog!) and resistor, and the rear passenger window was off track... this may have been a blessing in disguise! [slap] [drummer] [:D] Oh well... I do appreciate all the help from you guys though! [cheers]
 
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