I need to remove the tps sensor from the stock throttle body for my new one and i can't get that sucker off i must have been at it for two hours. after getting aggravated as anything i stripped the screws (yeah smart idea) anyway, i don't know what else to try, i tried wd40 i used a hammer, smaller Phillips head, bigger Phillips head. im thinking of taking a drill bit and try to dill the heads off the screws to slide the part off. here's how bad i f-ed it up.

 

The image didn’t work. Heat does wonders for stuck screws/bolts. Since your replacing the sensor anyways, you don’t have to worry about damaging the sensor. However, if there are other electronics in the area I wouldn’t use heat. You could damage the other components. But if the heads are stripped, then you might as well drill the heads off and slide the TPS sensor off. The screws are probably seized. Just make sure you have a new set of screws handy so you can put it all back together again. Good luck...

 

My bad I must've worded it badly. I meant for my new throttle body so I need to salvage the tps for the new throttle body.

 

I have no idea why Ford ever did that but I have had to use an impact screwdriver to take them off more times than not. They should be 6mm bolts so just go to your local hardware store and grab a couple. Then like petrock said drill them or cut the heads off and replace the screws with some bolts.

They could also be 8mm it's been a minute since I've replaced them so for the 25 cents per screw I would just buy some 6,7, and 8mm bolts to be safe.

 

I agree on replacing with hex-head bolts. Head size is only part of the equation though. Thread pitch is also important. If you don’t already know the thread pitch, then drill out the heads of the stripped screws and remove the TPS. Then remove the remaining screw stud and take the stud to your local hardware store so you can make sure you get the correct length & thread pitch replacement bolts.

 

I meant that the bolt size is 6, 7, or, 8mm. As in just go to the hardware store and buy the MM bolts. They don't vary on thread pitch like standard. I wasn't talking about head size, that's irrelevant.

Edit: Before someone comes along and says well yeah they do cause...X. I'm aware that you can certainly find various threads in specialty bolts. However the common MM bolts all have the same thread as opposed to standard bolts where you have to specify your thread pitch.

 

I also forgot to mention, diameter of the screw shaft is also important and variable. To avoid any issues, just take the remnants of the screw to the hardware store to make sure you get one that matches.

 

Use a power drill with a phillips head attachment. Push down with some force and that should crack them loose. I had the same issue with mine and that did the trick.