Here's my text document for doing the swap/conversion!
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FORD Part # M-9989-A1 converts V6 TPS plug to 5.0 TB's!!! (no splicing of wires) Supposedly this works...
1. Re-drill bolt pattern for V6 TB pattern (a gasket helps alot)
2. hack off MOST of the throttle arm, leaving the return spring portion,
the shape will resemble a diamond.
3. grind the remaining surface FLAT.
4. weld on MOST of the 3.8 throttle arm, less the return spring portion, just reuse the part the throttle cable hooks to.
5. making the crossover tube larger is a MUST and a big job! 54-55mm at least... that matches the flow rating of the 60mm TB (remember, no shaft to block airflow) The crossover tube must be tapered to 60mm @ the TB.
6. Re-use your 3.8 IAC (idle bypass motor)
7. SPLICE in the 5.0 TPS to your 3.8 wiring harness. The 3.8 TPS is "clocked" 90* off from the 5.0 TPS... and does not bolt on to the
5.0 TB. Use the wiring chart below.
Other than that, it is a "simple bolt-on!" (haha)
60mm is also the practical limit for the 3.8 Upper, the "choke point" can only flow about 550 CFM and the 5.0 TB is rated by FORD to flow 535-540 CFM. However you can weld the exterior of a crossover tube and port it
even more, figure about 2 to 4mm smaller being the minimum size for a
given TB. (65mm would need 61 to 63mm, etc.)
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5.0 TPS to 3.8 wiring harness wiring schematic: (for use without the Ford adapter)
5.0 TPS colors.................goes to..................3.8 harness
Green/Green..............................................Gray/White
Black/White..............................................Gray/Red
Orange/White.............................................Brown/White
base color/tracer (stripe) color
**** Note! Not all 5.0 TPS's have the tracer color, but it is listed
for those that do.****
When cutting the 3.8 harness wires, leave enough wire on the plug to reinstall it in the future
if the car is ever returned to stock condition. Use butt splices and shrink wrap to connect wires.
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Hope this helps Sarge!
BTW, U still buying those heads?
Rick Kilpatrick, AAS Automotive Systems Tech, Alamance Community College, Class of 99. 06 5 speed manual Mustang with Pony pkg : GT Mac Mufflers, true duals with one custom pipe. 2.5" system. GT bumper cover, all installed March 7&8 2006. AFE Stage 1 CAI, Motoblue Underdrive pulley, GT aluminum shifter knob, honeycomb rear blackout panel,and dash kit installed. Roush hood scoop and side window louvers installed. SS taillight trim has been installed, new alum. GT steering wheel installed.
