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Old 05-01-2010, 06:35 PM
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TPS Torx Screws

Anyone have a tip for getting these F'n screws out of the TPS without rounding off the T20 torx bits (99 TJ 6 cyl)? I know they're thread locked in there but WTF!!

I've rounded 3 bits with nothing to show for it. I've sprayed it and I'm using 1/4 in drive torx bits. They're firmly seated in the head but I can just watch them bend as I try to loosen them. Any help would be greatly appreciated.

BTW- first post here. I've searched tons of stuff and a lot of the returns are this site. Hopefully, someone can help me out.


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Old 05-01-2010, 08:46 PM   #2
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Not sure what kind you are using, so this may or may not apply, but maybe a better set of Torx sockets? All metals are not created equal and sometimes the more expensive sockets are in fact tougher/harder.

Oh, and I dont think theres a guy (or gal) on this forum that hasnt wondered who the hell thought all these Torx bolts on a machine made to get dirty, muddy and be reliable was a good idea. So all that said, welcome and good luck.

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Old 05-02-2010, 12:50 AM   #3
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2002 Sport: I used a Crafstman (Sears) torx bit for my TPS removal. Before using the Sears bit, I rounded off a piece of crap bit also. I also aligned the bit with a small extension into the screw before attaching the ratchet to make sure it was seated. You need a little pressure to keep the torx bit from popping out as you unscrew it. My new TPS came with a fresh set of mounting screws. (OEM) Hope this helps.
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Old 05-02-2010, 01:03 AM   #4
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x2 on the sears crafstman torx... they seem tougher than others I have tried.
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Old 05-02-2010, 09:04 AM   #5
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I agree with above. I used the Craftsman and they popped lose the first try.

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Old 05-02-2010, 09:46 AM   #6
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I just did my TPS even tho I have the wrong one to go back in. I couldn't get the TPS off in the truck. I had to pull the throttle body off too. Then with it in my hand it came off without much of a fuse. In the truck you really can't get a good motion going with the torx's bit.
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Old 05-02-2010, 12:41 PM
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Thanks for the input. The only issue I have with going craftsman is that I relocated to PR and the closest sears is near San Juan. Is there a certain type of alloy or hardened steel that I should look for?

Thanks again for the replies...great site.
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Old 05-05-2010, 10:40 PM
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Thanks for all the replies. After 5...count em...5 torx bits I finally got the screws out. I think they used JBWeld to put those things in. Anyway, once it was off I squirted it with contact cleaner and reinstalled it. No big changes there. I took it back off and soaked it in the contact fluid for about 3 or 4 hours this time and that was it. Amazing how touchy that sensor is. Saved $100 for now so I'm happy.

Thanks again for the advice.
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Old 05-06-2010, 01:01 AM   #9
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if the torx has any play in it at all it will round off. make sure the right torx is used should not be any play at all.
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Old 05-06-2010, 09:13 AM   #10
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What oldman said is very true, you need to make sure your using the right size. I see people using too small torx bits all the time and yes it will mess up your bit or worse strip out your screw head. When your using a ratchet and torx bit on the larger screws counter torque and lots of pressure is a must.


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