Help! (throttle body issue)
 

Over the last year, I have gone through 3 different throttle body shafts ... they keep breaking on me and I am getting pissed off. The first time, I had thinned the shaft with a grinder and figured that was why. The second time, I left it alone, but the screw for the damper had gotten loose and thought that was the problem, but i am not so sure now. The third time happened just yesterday and luckily the pick n pull had an escort GT that had a replacement (auto) for $40. It happened after going full throttle for a moment.

Prior to this, I had:
-set the pedal stop to a very conservative level (full throttle was about 90% open)
-made sure the damper was engaged
-loosened the tension spring one notch
-lubed the cable
-verified that the throttle stop was doing its job rather then the throttle bore
-I also tried to roll on throttle with a light foot when I went full on rather than jamming it down.

Only thing that I can think of is that I did not have a TPS attached but i dont see how that could make any difference.

Can anybody please help me?

holy shit. i have never done that. i even thinned out one of mine when i ported it.

the only time I had that happen was when the stop at the throttle body wasn't making contact and the shaft was taking all the load from the cable. There's not much else left in the equation since the cable IS connected to the cam that hits the stop...:dunno:

How the hell did you manage that...I thinned my shaft quiet a bit, it's been like that for like 3-4 years now, never had any problems.

You say you didn't have your TPS connected? Is that the case all three times? Not sure what the TPS does as far as stability on the 1.6's but I can only assume that's where your problem is since everything else is ok.