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TT AWD TBSS Jeep
TT AWD SS Pwrd Jeep
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5,825 Posts
Discussion Starter · #1 · (Edited)
Well, many have done it. You will see high idle, and retarded timing, maybe even glowing headers/manifolds.

1. Remove black plastic cover over the motor/gears.
2. Remove the middle gear, dont worry about position, doesnt matter
3. Rotate the throttle blade, and notice where the plastic stopper
hits the aluminum housing. Start with removing the aluminum.
4. Remove a little aluminum with a dremel tool and you will see blade close
some. If you run out of aluminum, you can remove some of the plastic.
Just dont remove too much plastic to the point of weakening it.
5. Re-attach and monitor comanded throttle until you see higher numbers
than zero, mine is usualy 7-12ish. You will also see your timing come back
6. Repeat till acomplished, assemble cover, then end, else go to step 7
7. If your here you really really really ported too much, get out the filler/bondo
8. Smooth a very thin coat of filler and sand smooth with 220, 330, 400, 800

NOTE, if you don't want to use filler, you can do multiple layers of acid etching primer

9. Inspect gap, and sand areas until they are even all the way around,
and closer by middle. You can do this from front to back of TB to
make it an even diameter all the way through.
10. When you are happy with your fill level, Paint with acid etching primer,
and apply quite a few coats (Even more if not using filler)
11. Sand with 330, 400, 600, 800, 1000, 1500, 2000, 2500, even 3000 if you
want too. Keep going until its smooth as glass, when your done it will
be better than polished alluminum ever could be.
12. Repeat steps 7-12 until your happy, assemble cover, and your done.

If you dont want the ugly green primer look, you could paint the color of
your choice, then clear coat several coats, then repeat the sanding process.

Good luck with your fix!!
 

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Premium Member
TrailblazerSS
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1,293 Posts
I would run a stock TB personally. It's actually proven somewhere on here a ported one takes a little power away from you. However, yes I know the throttle response is improved. :dunno:
 

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Premium Member
2007 TBSS AWD
Joined
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31,504 Posts
I would run a stock TB personally. It's actually proven somewhere on here a ported one takes a little power away from you. However, yes I know the throttle response is improved. :dunno:
Actually, I have never lost power but the gains are minimal if anything on a bolt on or cam only truck running a stock manifold.
 

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Premium Member
2007 TBSS AWD
Joined
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31,504 Posts
Huh?! I don't think I lost anything just more responsive now..elaborate please...
I think he is refering to a post from a few years back that I vaguely remember. Something about Alvin testing an LS2 car TB and making a couple hp less then with the stock TB on a cam only truck... IIRC

However, that has not been my experience. It is hard to quantify gains or losses of 1-2hp on a chassis dyno.
 

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Old but not Dead Yet!
TrailblazerSS
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9,572 Posts
Good info man. Thanks.
 

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Premium Member
TrailblazerSS
Joined
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1,293 Posts
I think he is refering to a post from a few years back that I vaguely remember. Something about Alvin testing an LS2 car TB and making a couple hp less then with the stock TB on a cam only truck... IIRC

However, that has not been my experience. It is hard to quantify gains or losses of 1-2hp on a chassis dyno.
+1 yeah, I dunno. I've heard the throttle IS extremely responsive after porting it though.
 

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Premium Member
TrailblazerSS
Joined
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1,350 Posts
If done by a mail order service, just make sure they flow test it. I got a used one for $25 and sent it away to be ported. Kept the stock one just in case. Once installed the ported one is real responsive.
 
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