Swampy
Dodge Dakota
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1/05/2013
05:38:47
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 Subject: V-8 TB option
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Message:
94 Dak, 3.9L, 42RH.
I went to the junkyard today and found a V-8 TB from a 95 Grand Cherokee, 5.2. The cables from the Jeep were different lengths from what I needed. The distance from the gas pedal to the firewall is also different, so the swedged ball stop rendered the Jeep cable completely useless. There were no other likely donors today, so I came up with a solution others may find useful.
I was able to use the cables and bracket from my 94 3.9, which has the plastic block on the butterfly shaft. The cables/bracket for the Jeep used a different throttle cable, a ball/socket arrangement. I could have shopped around for who knows how long, but that is not my nature.
The idea was to put the shaft from my V-6 TB into the V-8 TB. Thats where things got hairy... The V-6 TB shaft is thicker than the V-8 TB shaft, and will not plug and play. The slot on the V-6 shaft is narrower than the V-8 shaft, and the V-8 butterflies will not fit.
Here's how to get around it, if you are so inclined; but, BE FOREWARNED: THINGS MAY NOT GO AS PLANNED AND YOU COULD END UP WITH TWO WORTHLESS TB'S. That said, it worked for me. Here goes:
1) Remove all the sensors, and the cable bracket from your V-6 TB. You will use them later.
2) Remove the four butterfly screws and slide out the butterflies. They will only come out from the bottom of the TB because the slot is angled at the ends.
3) You will see that the part of the butterfly shaft where the screws thread in is enlarged from the screws poking out and pushing the shaft metal out. I suppose this is because the threaded holes were intentionally made small at the end to provide a tight press fit to keep the screws from coming out at the wrong (any) time. But I am not an automotive engineer, so I could be wrong. The point is, you need to take a small, flat jewellers file and file those high points off,
4) Now you can push the butterfly shaft out. If you need to, take a small block of wood (I used a small wire brush handle)and a small ball peen hammer to tap on the throttle position sensor end of the shaft. If you turn into Magilla the Gorilla when you put a hammer in your hand, you might want your wife to do this part. Also, pay attention to how the return spring goes on to the shaft and TB housing. Take a picture with your smart phone , or draw one if need be.
5) Do the same steps, 1 through 4, on the V-8 TB.
6) I know your'e gonna do it, so go ahead. Try to put the V-6 butterfly shaft into the V-8 TB. IT DOESN'T FIT! Read paragraph three again, and then proceed... (DISCLAIMER: If at this time, your V-6 shaft slides right into the V-8 TB, I am MUD and you are extremely fortunate, as half (only half), of your work has been saved!)
7) OK. Now we have to do two things... Make the V-6 shaft fit the V-8 TB; and, make the V-8 butterflies fit the V-6 shaft Now is a good time to notice that the holes for the V-6 and V-8 butterflies are in the same place. Finally something going our way! Unfortunately, now is also the time that you may potentionally ruin one or both TB's. So pay attention and be carefull!
8) Use a small drift punch and ball peen hammer. I used a 1/8 inch punch and an 8 ounce hammer. Stand the V-6 (or 8, doesn't matter) TB on end, with the TPS Sensor end down, and tap the roller bearing out, alternating side to side, always remembering that you are going to use this bearing again (V-6). The bearings are staked in, but the TB metal is very soft. The aluminum TB stakes are no match for the bearing steel. They are also no match for the tool steel of your punch. Swallow your pride if you must and ask your better half for a favor, (you can always return it later!) Flip the TB over and remove the other bearing in the same manner. I found it easier to temporarily reinstall the cable bracket for this side. Do the same on the other TB. Set aside the V-6 bearings for use in the V-8 TB.
9) Now you have to lenghten the slot in the V-6 butterfly shaft to accomodate the V-8 butterflies. I used a hacksaw blade and a small flat jewellers file to do this. As I previously stated, I am not an automotive engineer... Use the V-8 shaft as a reference, and make the slot in the V-6 shaft long enough to slide the V-8 butterflies in, with about 1/16th inch extra on each end to allow for the butterflies to align when you reinstall them in the TB bores.
10) The V-8 TB shaft bores must be drilled out to accept the V-6 shaft. I used the V-6 TB as a gauge to select the proper sized drill bit. After drilling, I needed to dress the shaft bores with a round jewellers file until the V-6 shaft fit with a very small amount of play.
11) Press the V-6 bearings into the V-8 TB. I used a 9/16 craftsman deepwell socket and the 8 ounce ball peen. I did not stake the bearings in, as they have no where to go. Begin with the TPS side down and install the bearing in the bracket side, Then set the bracket side down on the 9/16th inch socket, as a spacer, and use a second 9/16th deepwell socket to drive in the TPS side bearing. (you can NEVER have too many tools!)
12) Reverse engineer everything back together, using some blue Locktite on the butterfly screws. The butterflies only go in one way. There is a number 11 stamped on each. You know they are in right when the screw holes line up and the whole assembly springs shut all the way to the idle stop (screw adjusted fully out,tamper seal removed).
Now you have a V-8 throttle body with your stock V-6 cables. Sweet!
The whole job took about two hours.
Swampy in NEFla. PBWY
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