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TOPIC: 1998 Ford Expedition 5.4L BBK 75 MM Throttle body Groove

98 Ford Expedition 5.4L BBK 75 MM Throttle body Groove 05 Jun 2016 00:12 #1

  • Tracy Gallaway
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Here is a Groove job on a 98 Ford Expedition, with a BBK 75 MM bore aftermarket throttle body. This nice customized Expedition is owned by Danny Jones, a really nice guy. Danny knows a thing or three about engines and vehicles. He has been around engines and mechanical things most of his life. Danny was an Aircraft Mechanic and Airframe sheetmetal specialist during the Vietnam War. He repaired battle damage from flak and SAM missles on B-52's. He said that he repaired the B-52's that somehow survived massive damage received in bombing runs over Hanoi and Haiphong in the Christmas Linebacker II bombing offensive in Dec. 1972. He said he repaired one B-52 that had a hole in the fuselage so big he could have walked through it!

And Danny has taken exquisite care and done many upgrades to his 98 Expedition. The 5.4 L engine has ceramic coated headers, dual exhaust, a K&N cold air intake, underdrive pulleys, Franz oil and fuel filters, an air-oil separator, Fitch fuel catalyst, electric dual fans, and more. He's replaced the rear O2 sensors recently, and plans to do the upstream's soon. And the ECU has a performance chip.

And of course the BBK 75 MM performance throttle body, which is where I come in. This was a straightforward Groove job. The aluminum casting was harder metal than factory Ford TB's I've done before, so it took longer to Groove. I was careful and deliberate with it, you will see in pics here how I started the job, the TB is in the Panavice at one angle. I then reposition as I go so I'm cutting in a close to level plane. I cooled the bit in oil after each cut, and both TB and the flex shaft Dremel got hot! Got a decent large Groove, no breakthroughs.

Danny re-installed the TB, and I did the re-learn drive. I noticed a nice boost in power just past idle. I intentionally turned the idle adjust screw on this TB 2 turns in, before Grooving. To place the plate a bit downstream, to prevent a harsh power surge off idle, and repositioned the screw afterwards. You can see the closed plate sitting upstream of the Groove. Still, it took awhile to get used to the throttle and power of this Ford, it has gobs of torque.

Overall a successful Gadgetman Groove job! Nice power boost, a really nice customer, and a happy engine!
Tracy Gallaway
Founder and Constant Aide to Gadgetman
Gadgetman Reno, NV

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Last edit: by Tracy Gallaway.
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