I just got a smoke machine hooked up to the intake on my newly acquired '03 4.0L SOHC & I see plenty of smoke coming from the TPS. It is already screwed down very tight & the screws are rusted well in place. It's gonna be a struggle to remove them I can tell. Anyone know is there supposed to be a gasket there? I could not find any mention of such a problem in the forums. Thx in advance.

EDIT: I'm just going to pull this thing out tomorrow one way or another & have a look at it. Probably need to get new fasteners also.

 

So I've no idea how it's supposed to seal. I'm guessing the leak is from the TB side. Any suggestions on finding two TPS replacement screws?

 

Is it leaking smoke from around the shaft itself? Is it loose?
Would a carefully applied blob of grease seal it if only temporarily?

 

Thx for responding. I discovered the leak is from the butterfly valve shaft seal (its 20 years old after all) but I'm not ready to replace the throttle body (need to see what they sell for). I used RTV on the TPS in an attempt to seal it there. Will do another smoke test soon. Do you know it I can I replace that seal myself?

 

I do not.
RA lists one replacement TB for $175. Two other Ford specific sources listed none.
There must be other sources.
Best o'luck.

 

Thx for that info. I've had cars that used o-rings on the tps sensor to prevent those shaft leaks but I notice that replacement sensors dont come with them either. I suppose I could find one that might work if the RTV doesn't seal it off.