Especial86

iTrader: (1)

Yes on opposing sides of the throttle blade.. why did you take the TB apart?
Are you running the stock tb?

ng8264723

To paint it. There was nothing (that I know OF) wrong with it. It is pretty now. It may or may not work sigh...............

Especial86

iTrader: (1)

Ohhhhh ok this is good news.. you probably still have it put together wrong then.. You gotta "preload" the TPS (for lack of a better description. The other TPS is integrated into the stepper motor, you can't really mess that one up..
I wouldn't be surprised if this is what's wrong.
But at 60psi line pressure I'm curious to see if your possibly getting too much fuel pressure and it's dumping too much gas every time the injector opens and closes.. you really need to adjust the injector pulse width modulation for higher fuel pressures, so now everything is starting to make sense to me.. If you can turn it down to 40 - 45 psi at the regulator you installed you might also cure whatever injector pulse width codes or issues that the mechanic said you were having.

Might be worth seeing if you can get your hands on a new TB for some instant gratification. I changed mine for a new one when I swapped motors and I noticed all sorts of little improvements including a much smoother/low idle around 6-650 rpms.. My old TB I had to request a higher idle via ECU/tuner to compensate for what I can only describe as a floating low idle. Couldn't get it to stay above 550 rpms without requesting 700rpms, when it felt like it.

I'm prob gonna run the GT500 TB like blownford on my whipple sooner than later and port the snout/TB flange while I'm at it..

ng8264723

I was doin some reading and I found that the TPS controls the injector pulse width. Could a bad TPS cause a no start??

Especial86

iTrader: (1)

Yup.
The ecu is completely powerless to control the engine without it..

redfishtd

The PCM sends pulses to TB, the card decodes pulses and drives motor . Any signal failure will cause PCM to shut it down if mismatch occurs . It compares gas pedal signal to Throttle position sensor on side of TB . It can not tolerate a difference for safety reasons . This is fly by wire . It is responsible to keep the system from going runaway . You have heard of vehicles accelerating and out of control and the brakes not being able to shut it down as the throttle is stuck full on . That's why the PCM shuts it down .
My orig 05 TB failed due to a bad series of TB made at that time, it would just quit intermittently . I cleaned and changed TPS it still did it . Improved version fixed it . Stopping is more important than going ,one can kill you .

ng8264723

I ran the TPS question by the ford guy. He said it should of thrown a code for the tps. He also said it was possible. I will just replace the TB when I get it home and see. From what I have read others have had bad TPS's with no codes..

Especial86

iTrader: (1)

TPS codes are hit or miss, I know I had a bad TPS but no codes on my old TB..
once you get it home and get yours eyes and hands on it you will probably have this thing running in minutes. I'd check the wires/connectors to the TPS and TB for anything obvious, and double check any wires you spliced per the Roush install manual.
I really don't like the idea of the ignition hot splice on the pcm for what ??intercooler pump?? Who knows what..
I also hope you have your old PCM lying around.

There has just been too many hands and opinions on this truck, and I really don't personally trust many "mechanics" on the 5.4 3v. Nobody takes the time nor has the time to know the quirks of motors these days.

But have no fear, I guarantee we will get this thing running.

Eric Kleven

If the fresh throttle body doesn't fix the problem, I might suggest putting in stock injectors and plugs just to see if it will start on them.

Long pulse width + 48lb/hr injectors = LOTS of fuel...

Hope it's just the throttle body, though.

ng8264723

After the stock injector stuck open filled up my cylinder with fuel and hydrolocked it I threw them away. It bent a rod. The plugs I should of saved but tossed