Originally Posted by Clinton
Drill them out then get new screws from the dealership, they are cheap enough. They tend to rust out pretty bad. You could try using stainless ones from a hardware store as well.
lol, I fixed the truck in question a long time ago Clinton.
There are two ways to remove the screws from the TPS.
1. Drive the truck around and get it nice and warmed up first. Then when you come home, unplug the connector from the TPS, and then grab a pair of vice grips, and something to cut the heads off of the screws, be it a grinder, or a Dremel like tool. Cut the heads off of the screws, and then pull the TPS off of the screw shafts. Once the TPS is off, get a good tight grip on the screw shafts, and turn them loose. The screws have a gracious amount of locktite on them from factory, and warming the truck up is necessary to deactivate the glue due to the heat. If the engine is cold, then the glue is active and will not let go.
2. For those without access to a grinder, the easiest way to remove stuck and/or stripped out screws from the TPS, is to drive the truck around and get it nice and warmed up first. Then, when you come home, unplug the connector from the TPS, grab a pair of vice grips, and clamp then down onto the screw heads. Once this is done, turn the screws loose. The vise grips will probably make contact with the TPS body. If you can, turn the vise grips right through the body of the TPS. If the vise grips do not remove enough of the TPS body plastic, you will probably have to knock some of the old TPS off with a screwdriver. It is cheap plastic, so it should break easily. Eventually you should be able to get the screw out.
As Clinton said, you can get replacement screws pretty easily.