Explorer Throttle bodies

See http://www.veryuseful.com/mustang/tech/engine/ConvertingExplorer65mmTB.pdf for modifications to adapt the 65 MM Explorer TB to a Mustang

The stock Explorer linkage didn't come anywhere near fitting, so I made an adapter plate for the throttle linkage so I could use the 65 MM throttle body.

This is what I did:
Make a drawing of the position of the old throttle body linkage arm and its angular position relative to the centerline of the throttle body. Remove the ball stud off the explorer TB to make way for the adapter plate. Drill and tap a 10-32 hole in the linkage parallel to the TB shaft. Make an angle bracket out of 1" angle iron 3/8", drill a 3/16” hole in the center of each one of the legs. Then bolt it on where the hole was drilled & tapped. Then make a circular adapter plate out of 1/4" thick aluminum to bolt the two linkage arms together. Then bolt the aluminum plate to the existing linkage, and the angle bracket. Next mount the arm with the ball stud off the old throttle body on the adapter plate using the drawing to get the angle correct. You will need an aircraft type countersink for one of the bolts that secures the plate to the explorer linkage arm. It ends up being under the arm with the ball stud for the linkage. It works great and looks neat.

A trip to the welding shop with the explorer TB and the arm from your old Mustang TB would probably accomplish the same thing. I didn't have access to a welder, so I fabb'ed the plate in my shop. I took about 1.5 hours to do it, it was a measure, cut, and fit type of operation.

The red insert inside the Explorer TPS connnector pops out from the front with a little bit of careful prodding. Use a safety pin or a jeweler's screwdriver to do the job. Once the insert is out, you can remove the pins from the rear of the connector. You end up with a TPS with 3 wires with the pins still on them. Repeat the process with the connector from your old TPS and you can insert the pins in the old TPS shell. Re-insall the red center plastic part and you have custom made TPS that fits your new TB.