Converting an Explorer 65mm Throttle Body for Use on Mustang
The Explorer TPS is not the same as the Mustang, but it can be used if you install the stock connector in place of the Explorer connector. The center section of the connector can be released with a ice pick or small screwdriver and the wiring/pins can then be removed and placed in the stock connector which has been split in the same fashion. If you want to retain the stock TPS, you'll have to drill the stock TPS bolt holes larger to get them over the 65mm mounting holes as they have just a tad wider centerlines. The TB tab that slips into the TPS may be a little too long for the stock TPS (mine was) - it may need to be ground down to clear the top of the TPS and prevent binding. I found the adjustment of the stock TPS mounted was not easy, so I put the Explorer TPS on there and used 3 thin push-on spade conectors (just wider than the blades they push onto) for the TPS blades which I soldered onto the wire of the TPS connector I cut off the stock TPS. I used shrink tube (could use electrical tape) to insulate the connectors from each other as they are very close in the Expolorer TPS head. Pushed them on and then filled the TPS head cavity with RTV Ultra Black to keep them from being pulled off - see picture below for color codeing the connections. Works like a charm.
The 97 model 65mm TB has the boss for the 90° hard line elbow line that runs from the oil fill neck to the stock TB but it is not drilled nor does it have the elbow on 97 throttle bodies. I have seen some 96 models with the elbow. I cut the boss that the stock one is pressed into deep enough with a thin cut-off abrasive blade so that I could crack the side of the boss away, making removal of the pressed-fit 90° elbow easy. You might be able to get it out by simultaneously twisting (circle) and pulling on it. I then used a uni-bit step drill with 1/4" long step sections to drill the new hole in the 65mm TB boss to accept the elbow. I then inserted it with epoxy.
The throttle linkage ball is also "clocked" in the wrong position for the Mustang. I cut the linkage off an old 60mm TB and used it. The shaft is split at the end and where the factory slides the throttle bracket and return spring on it during assembly, they press the split end of the shaft and press it onto the slot in the throttle bracket. You'll see what I mean. I took a small abrasive wheel and ground the pressed halves of the shaft off so I could pry the throttle bracket off. I then noticed that the slot in the bracket when laid over the 65mm TB shaft split-pressing aligned the throttle ball in the correct clock position. If you don't grind the stock bracket too bad and the slot is intact, it will slide over the Explorer pressed shaft halves and create an alignment that is correct. I used a combination of a VERY good epoxy and a tech screw to hold the cut off 60mm bracket onto the 65mm bracket but it could be tack welded on the edges also. I now have both throttle balls on the 65mm TB. Here is a picture of a converted 65mm TB that will bolt on replace the stock 60mm.
Another way to convert the linkage is to cut the ball section off, turn it around and weld it back on in the correct orientation - see the picture below.
