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Old 01-31-2012, 12:51 AM
hlperez1976 hlperez1976 is offline
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Default 2002 3.0L Throttle body mod. 50mm to 60mm

Ok here we go. I wanted to use the lager throttle body on my 2002 3.0L. I read up on some of the post on here (50mm to 60mm) and went out on Ebay and bought a Duratec 3.0L from a 1999 Mercury Sable. That was a mistake.

The 1999 3.0L Duratec operated the opposite way (CW) from my 2002 3.0L (CCW) throttle body. I was kind of mad I didn't research better but the darn thing looks like it bolted up perfect. I try to see if I could have run my throttle cable and cruise cable to pull from the bottom instead of the top but it was a pain in the but to do so. So I had a brain fart. "Can I just mod. and rotate the blade in the 60mm to operate like the 50mm on my truck?"

*** Notes --- 50mm is the stock throttle body on my 3.0L on my 2002.
60mm is the 1999 3.0L Duratec throttle body I bought *********

So I bought another throttle body to use as a donor for the one on my 2002 3.0L. I took both throttle body apart. It was really easy.
- remove sensor
- remove screws on throttle body blade and deburr the shaft.
- pull on the lever side and the entire shaft and spring slides out.

I had to make the 60mm throttle body look like the 50mm throttle body on the lever side. So I cut 2 tabs to allow the lever of the 3.0L to clear for rotation. I used the stock 2002 3.0L (50mm) shaft and lever assembly as a guide to cut the material off the 1999 3.0L Duratec (60mm) throttle body. Also made a notch for the spring to rest in just like the the stock 50mm.

Carefully I matched up both levers and shaft side by side to orientate the angle I need the 60mm to be. I need the make the 60mm to rotate counter clock wise (CCW) now just like the 50mm. The 60mm was rotating clock wise (CW). I carefully marked both shaft on the same sides, both levers on the same sides. What I'm trying to do here is put my 50mm lever on the 60mm shaft. Carefully I gridded off the material from the shaft to the lever on both, removed the levers, clean up the shaft on the 60mm, then mounted the lever from the 50mm to the 60mm shaft. A tack weld to hold them together and it's done. A simple swap.

I cleaned up the sealed bearing on the throttle body and use some lithium grease to slip it all back together. I had to bend a part of the lever a bit so it can hit a tab. This will prevent the blade going past wide open throttle (W.O.T) when smashing the peddle to the floor. I still had to install the idle speed adjustment screw. I just drilled, tap and install the screw in the correct location on a tab that comes in contact with the lever when it closed.

All is left to do is port out the opening on my plastic intake on my 2002 Ranger to match the 60mm Duratec throttle body now.

Here's a few pics. Sorry i don't have step by step pics. I was in a time crunch at work and wanted to go home.







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2002 Ford Ranger Tremor,Sonic Blue, 3.0L.V6, automatic, 2 wheel drive, 2 1/2" lift, rear disk brake conversion, Volo chip
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Old 01-31-2012, 03:04 AM
btm757 btm757 is offline
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Default Re: 2002 3.0L Throttle body mod. 50mm to 60mm

nice write up
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Old 01-31-2012, 08:43 AM
CLOS99 CLOS99 is offline
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Default

Do you feel any difference, in performance.
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Old 01-31-2012, 11:01 AM
02BLUEdge 02BLUEdge is offline
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Default Re: 2002 3.0L Throttle body mod. 50mm to 60mm

You reminded me I have a Duratec TB sitting at the house for months now. I am interested to hear what results you achieve.
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Old 02-01-2012, 12:05 AM
hlperez1976 hlperez1976 is offline
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Default Re: 2002 3.0L Throttle body mod. 50mm to 60mm

***** I just followed someone else write up on here and another web sight. ******

After removing the 2002 3.0L plastic intake and carefully using a die grinder, i just removed the material that held the "o" ring in place. That diameter is 60mm. I filled up the opening in the intake with J.B. weld because I have to use a paper gasket now. The grove that held the "o" rig is now gone because I ground it away.

!!!! I noticed that the opening on top (I guess for the I.A.C. motor) is super thin and didn't think the gasket paper will seal it. Soooo I built it up with some epoxy. Just a small sliver will do about 1/16" tall. I finger it (LOL) for a bit until it look good and left it to dry. !!!

After the J.B. weld dried, I sanded it down flat with a orbital sander. 180 grit then 220 grit. It got it nice and flush now. I got some of that grey gasket paper material and cut out a gasket for the throttle body. ***Oh... I still used a small piece of that "o" ring but only for the top and side part of the I.A.C. motor opening. Also I used a little bit of silicone on that area just for added insurance it won't leak internally. Bolted everything back on and let it warm up to operating temp. Just had to tinker with the idel a bit and it was good to go.
What did I get out of this????
It sounds a bit more louder at the intake now and the throttle is way more responsive on take off. In the higher RPM range ... not too sure I notice any difference. Just a way better throttle response and it jerks my head back a when i take off now. SAWEET!!!









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2002 Ford Ranger Tremor,Sonic Blue, 3.0L.V6, automatic, 2 wheel drive, 2 1/2" lift, rear disk brake conversion, Volo chip
"If it brakes, replace it with something better.
What don't kiss you makes you stronger."

Last edited by hlperez1976; 02-01-2012 at 12:28 AM.
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