Converting an Explorer 65mm Throttle Body for Use on Mustang
The Explorer TPS is not the same as the Mustang, but it can be used if you install the stock connector in place of the Explorer connector. If you want to retain the stock TPS, you'll have to drill the stock TPS bolt holes larger to get them over the 65mm mounting holes. The tab that slips into the TPS can also be a little too long for the stock TPS - it needs to be ground down.
Some models of the Explorer65mm TB have the boss for the 90° hard line elbow line that runs from the oil fill neck to the stock TB but it is not drilled nor does it have the elbow on 97 throttle bodies. The hard line in the stock 60mm TB is pressed in, so if you twist it back and forth while pulling on it, it will back out making removal of the pressed-fit 90° elbow easy. Then drill the new hole in the 65mm TB boss to accept the elbow. I then inserted it with epoxy.
The throttle linkage ball is also "clocked" in the wrong position for the Mustang. I cut the linkage off an old 60mm TB and used it. The shaft is split at the end and where the factory slides the throttle bracket and return spring on it during assembly, they press the split end of the shaft and press it onto the slot in the throttle bracket. You'll see what I mean. I took a small abrasive wheel and ground the pressed halves of the shaft off so I could pry the throttle bracket off. I then saw that the slot in the bracket when laid over the 65mm TB shaft pressing aligned the throttle ball in the correct clock position. If you don't grind the stock bracket too bad and the slot is intact, it will slide over the Explorer pressed shaft halves and create an alignment that is correct. I used a combination of a VERY good epoxy and a tech screw to hold the cut off 60mm bracket onto the 65mm bracket but it could be tack welded on the edges also. I now have both throttle balls on the 65mm TB. Here is a picture of a converted 65mm TB that will bolt on replace the stock 60mm. You can also cut the ball off and re-weld in the correct orientation.
When I tried to install the Fox TPS on one Explorer TB, it did not go well as the mounting holes were spaced further apart and opening the TPS holes too much made for a sloppy install. An alternative is to use the Explorer TPS, cut the connector off the Fox TPS and install it on the Explorer TPS. You will need some thin push-on spade connectors, shrink wrap to cover them as they will be close to each other in the TPS when you push them on, and some RTV Ultra Black to fill the TPS cavity once it’s all hooked up to secure the wires in the TPS. Use the color coding shown below – orange on the left, green in the middle and black to the right.