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Dodge Ram 1994-2001: How to Repair and Replace TPS

Are you having issues with a surging idle? Maybe it's time to replace your throttle position sensor, which you can easily do following the instructions listed here.

By Neftali Medina - July 10, 2015

This article applies to the Dodge Ram 2nd Generation (1994-2001).

A bad or worn throttle position sensor (TPS) will make your truck act all kinds of crazy. From surging and erratic idles to poor fuel consumption. Diagnosing the TPS is also finicky, as the many of its symptoms are relative to most of the vacuum and idle controls found on the vehicle. In most cases, a code will also accompany the failure of the TPS, and once that occurs, you can easily take care of the problem. There are two common ways to approach a failing TPS: one is to replace the unit in its entirety, while the other is more of a quick patch that will eventually have you replacing the unit regardless. However, the temporary repair is a viable option when the budget is important. The following instructions explain how to complete both the full TPS replacement and its repair.

Materials Needed

  • Torx bits
  • Drill
  • 1/8" drill bit
  • Electrical tape
  • Carb cleaner
  • Screwdriver

Step 1 – Remove the TPS sensor

  • Use a Torx driver to remove the mounting screws.
  • Disconnect the sensor from the harness plug.
Figure 1. Disconnect the harness plug and remove the Torx screws.

Step 2 – Repair the TPS (optional)

If you are on a tight budget, you can try using this temporary repair procedure that allows the TPS to read the airflow better. However, this only lasts approximately six months before the sensor will fail completely.

  • Use the 1/8" bit to drill a shallow hole into the sensor. Stop drilling before going too far and damaging the actual sensor.
Figure 2. Drill a hole into the sensor.
  • Spray some carb cleaner into the freshly drilled hole, and spin the sensor around to clean it out.
Figure 3. Spray some carb cleaner inside the TPS.
  • Once finished, allow it to dry, place a piece of electrical tape on the hole, and use some silicone to completely seal it.
Figure 4. Seal the hole.

Step 3 – Install the TPS sensor

  • Either take the replacement or cleaned unit and install it back onto the throttle body.
  • Tighten the Torx screws.
  • Finally, reconnect the wire plug.
Figure 5. TPS unit installed.

Featured Video: How to Replace TPS

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