Throttle body shaft removal – How to

[trevr]

I spent some time looking for a post on how to do this, but couldn’t find anything, so I put this together to help anyone else on needing this info.

The process is really easy; it will take you longer to read this than to actually do the work. The pictures aren’t really necessary, but they will help grab other's attention while searching…

Two things need to come off for removal, the TPS and throttle body plate. Be careful removing the throttle plate screws, they strip easy. Found it easier to use a large screw driver instead of a Philips head. Once the screws are removed, rotate throttle to open and slide the plate out.

You don’t need to remove anything from the pulley side of the throttle body, but you do want to relieve the tension hooks on the pulley springs.



Next step is to tap the shaft out of the body. Use a rubber mallet using a series of firm taps on the TPS side of the shaft will slowly get things going, then continue gently till it is fully out.

That's it for removal, install in reverse order. This is a good time to clean things up, you will have full access to bearings, nooks and crannys.

Here are some post pics



TPS Side



Pulley Side


Modified by trevr at 9:36 PM 1/8/2010

[float_6969]

Nice! Thanks for the writeup.

[rico05]

Cool. But...the point is what now?

[trevr]

I've ported the intake plume to mate with ka24de throttle body, but now I need it to accommodate a hi-throttle pulley that will only fit on the ca18det shaft.

[trevr]

I went a little further with this, so here is how you assemble the pulley springs assembly.

Here is the order of installation from left to right.



Like I mentioned above, I'm swapping shafts from the KA tb to the CA tb, so I have a little more ease in assembly since I have room to move things around with the shaft out of the body.

Just to get this out of the way, I'm going to say "slide down the shaft".... alot

So grab piece 1, slide it down the shaft with the flat side towards to back of the tb when shaft is in the closed position.



Piece 2 and 7 are similar, but 2 has a larger area cut out where 7 just has a slot on it. So with piece 2, slide it down the shaft with the cut out area towards the back of the throttle body.



Then, take piece 3 and slide it down the shaft



There are two parts for piece four, first slide the cylinder on, then the spring over that and position the spring as shown in the picture below



Now, I just realized I forgot to take a picture for pieces 5 and 6. Piece 5 slide over everything and position it has low as it will go, with the collar facing away from the body assembly. Piece 6 is the cap for the top of the spring. You can see how piece 5 is position in the next picture.

Piece 7 is where you are going to start to load the springs. As shown in the picture below, you want to first position the spring into the slot on piece 7



Once you have the spring in the slot, you need to turn piece 6 counter clockwise till you can slide it down the shaft. This will give you resistance since you are loading the spring. If you do this correctly your throttle body should have resistance when you open the throttle plate and the spring should close it.



Next grab piece 8, the larger spring... slide it down the shaft, and then position piece 9 over it like this



Piece 10 is a locking washer, position it as shown in the pic below.



Then push down on the washer and you should be able to rotate in a way to lock everything together



Now this is the hardest step of all, you have to get tension on the larger outter spring by moving this



You need to move that tab back so it sits on the pulley with resistance. I found it easiest to use a piece of string to pull it back to where it needs to be and hook it on the pulley. Sorry for not having a pic showing how to do this step. Below is what you will have when you are done



Once its on and snaps close with some force, you can finish with the washer and locked nut.

Here's what mine looks like with the hi-throttle pulley


Modified by trevr at 9:40 PM 1/8/2010

[zombieslider]

sweet, i def took mine apart and then started on another project and that was months ago now i dont have to fiddle with it for a cpl hours.