Home » Technical

How to install BBK’s twin 62mm throttle body for the 2005-2010 Mustang GT

By - December 22, 2010 – 4:03 pmNo Comment | 5,511 views

The 2005-2010 Mustang features an electronically controlled dual throttle body that does an excellent job of metering air into the intake manifold. Of course, more air is better, and several aftermarket companies have developed throttle bodies with larger openings that can feed more air into the Mustang GT’s 4.6-liter V8.

BBK Performance in Temecula, CA specialize in throttle body applications and has developed a 62mm unit for the 2005-2010 Mustang GT. The throttle body is CNC machined from 356 aluminum castings and is designed to increase air flow over 30 percent compared to the stock throttle body. At a retail price of $299.99, it’s also a relatively cost effective way to add horsepower. BBK claims that independent dyno tests have yielded gains of approximately 15 horsepower and 20 lb-ft torque on an otherwise stock Mustang.

The installation is relatively simple and involves removing the stock intake tube and throttle body, transferring some of the components from the stock throttle body to the BBK unit, and then reinstalling. In some cases the “check engine” light can come on, in which case the voltage of the throttle position sensor needs to be adjusted. BBK has detailed instructions and a video on the company’s web site showing how to adjust the voltage, as well as full installation instructions.

We recently went to BBK’s facility to follow along during one of their installations, and we’ve documented the process to show you how it’s done.

The BBK twin 62mm throttle body is constructed of 356 aluminum castings and is designed to increase air flow by 30%

The rear view of the BBK twin 62mm throttle body

Start by disconnecting the battery. Next, disconnect the positive crankcase ventilation (PCV) hose connection from the air intake tube.

Disconnect the mass air meter connection by releasing the locking tabs and pulling them away from the intake system.

Loosen the hose clamps near the air filter with an 8mm socket wrench.

Loosen the hose clamps near the throttle body with an 8mm socket wrench.

Once the clamps are loosened, remove their air intake tube and set it aside.

Disconnect the throttle position sensor (TPS) from the left side of the throttle body by pulling back on the red locking clips and squeezing the connectors while pulling them away.

Disconnect the electric motor harnesses from the right side of the throttle body by pulling back on the red locking clips and squeezing the connectors while pulling them away.

Use 8mm and 10mm long socket wrenches to remove the nuts holding the stock throttle body in place. This one has been removed before and uses hex-head bolts as a replacement for the stock studs.

Remove the throttle body from the intake manifold. The stock O-ring behind it will be reused.

Unscrew the TPS sensor from the throttle body using a Torx wrench. Be sure to pull it straight off, and do not twist the insides or it might break.

Here is the TPS sensor removed from the stock throttle body.

Bolt the TPS sensor onto the BBK throttle body using the two factory screws.

Remove the perimeter screws from the electric motor housing using a Phillips screwdriver.

Once unbolted, remove the electric motor housing from the stock throttle body.

Once the electric motor housing is removed, the plastic spring cap will uncoil. Be careful not to lose it.

Fit the plastic cap spring and the electric motor housing cover onto the BBK throttle body and loosely bolt it on. Once this is done, the plastic spring cap needs to be rotated. There are tabs on the plastic cap spring that need to line up with landings in the motor housing cover. To achieve this, use a screwdriver to rotate the spring cap counterclockwise approximately 180 degrees unil they line up. If this is done correctly, the throttle body should snap shut on its own after being opened up manually.

Once the throttle body is working correctly, bolt the electric motor housing cover down completely.

The BBK throttle body is ready to be installed onto the intake manifold.

Bolt the BBK throttle body onto the intake manifold using 8mm and 10mm long socket wrenches.

Reconnect the throttle position sensor (TPS) onto the left side of the BBK throttle body.

Reconnect the electric motor harnesses onto the right side of the BBK throttle body.

Tighten the hose clamps near the throttle body and the air filter with an 8mm socket wrench. Plug the PCV hose back into the air intake tube, reconnect the MAF sensor and reconnect the battery. The installation is complete!




coded by nessus

Leave a comment!

Add your comment below, or trackback from your own site. You can also subscribe to these comments via RSS.

Be nice. Keep it clean. Stay on topic. No spam.

You can use these tags:
<a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <s> <strike> <strong>

This is a Gravatar-enabled weblog. To get your own globally-recognized-avatar, please register at Gravatar.