Hey guys. I ran into a snafu the other day and I'm hoping someone can help me out. I was adusting my tps voltage and broke the head off one of the torx screws that holds the tps in place. It didn't break off flush with the throttle body so I still have some hope of getting it out without drilling. There is about 3/8" still sticking out. I was going to put some vice grips on it and try to baby it out but I really dont want to break it again. Does anyone know any tips or tricks for this type of situation? Thanks in advance.

 

Remove the TPS and you should be able to get it out with pliers.

Broken bolts and screws are easy to get out (if they're not stripped). Studs are a PITA.

 

drip hot wax down in the threads before you try to work it out with the grips, it adds lubrication and makes it a bit easier.

 

Thanks for the tips. I dont think it is stripped, but it think its probably pretty corroded in there. I may give the hot wax thing a try. Does that work better than WD-40 or sililar lubricants?

 

better in my opinion. But im just another guy, so what do i know?

 

If it's corroded, I'd use some PB Blaster.

 

This is a common problem and I am surprised that someone hasnt made a kit to sell. They could include a drill bit, helicoil, and bolts. I drilled mine out and went slightly bigger but the TPS slots had to be opened slightly. Good luck.

 

Heat the screw and hose it down with PB blaster or something like PB blaster while it is still hot. Make sure you dont heat the screw enough to lose its temper, around 300-400 deg should work.

You could also try hitting it (like driving a nail) sharply with a small hammer then go after it with the vice grips.

 

Had the same happen to mine, it was so brittle it broke off when I put pliers on it. I drilled it out and tapped slightly larger threads in - IIRC it was M5x0.8 and I went to the SAE that worked out to half a size larger. Can't remember off the top of my head. I didn't have to enlarge the slots in the TPS for them.

 

Thanks for the size. I wonder if I went to large. Now I am going to have to check.

 

Well don't take my word as gospel truth, it was quite a while ago. Just make sure you double check before starting any drilling or tapping.

 

Thanks for the feedback guys. Thats good to know that I can tap it out slightly larger without having to modify the tps itself. I'm going to try to break it loose and remove it with pliers first but I'm affraid I will end up having to tap new threads. It broke of VERY easily the first time so we'll see what happens. Hopefully I will get it fixed this weekend. Thanks again.