You need to bore out your intake manifold to match the bore on the adapter (which is 68mm). Simply bolt the adapter onto the manifold, scribe a line, and grind away with a burr and die grinder. Finish with sand paper and do a light polish.
Second step is to adapt the cable linkage. This will require some fabbing/welding to merge the linkage of a 4.0 tbody to the linkage of the 4.7 tbody. I'll make another post for this.
There are a couple things to look out for when sourcing a Dodge 4.7 throttle body. This is based on my time at the yard pulling three different throttle bodies so I make no promises as to the accuracy of my findings:
- The throttle body you want will come from a Dodge 4.7 V8
- Some Dodge 4.7 throttle bodies are 65mm and some are 68mm. The TDS adapter accommodates the 68mm. The 68mm is easy to distinguish as it has "68mm" stamped right on the plate. The 65mm has no stamping. There is a year where the 4.7 v8 switched from 65 to a 68mm but I'm not sure what year (somewhere around 2000?). The 65mm will work but you would have a step where the throttle body meets the adapter.
- There are two castings of the 68mm throttle body. The difference is in the style of IAC they accommodate. One allows an IAC that is held on with one bolt, the other allows an IAC that is held on with two bolts. The two bolt style has the same IAC found in the Jeep 4.0 up to 2004 and the single bolt style uses the same IAC as found in the 2005+ Jeep 4.0. So you need to pick a throttle body from the correct doner vehicle to match with the style of IAC on your Jeep.
- In my junk-yard hunting, I found the correct 4.7 tbody for Jeep 4.0's up to 2004 were found in the Jeep Grand Cherokees WJ (up to 2004). The correct 4.7 throttle body for a 2005+ Jeep 4.0 were found in the second gen Dodge Dakota Durango (2000(ish) up to 2004). The 65mm throttle bodies were found in early second gen Dodge Dakota/Durango (pre 2000(ish)).
- The TPS sensor appears to be the same on all 4.7 throttle bodies and is a match for the TPS found on the Jeep 4.0 throttle body... plug and play.
- Once you get the correct 4.7 throttle body, your existing 4.0 IAC and TPS should swap right over.
Just waiting to hear from Russ on pistons etc. Meanwhile I'll start the head work and finish up the tbody.
