BBK Throttle Body Intake Plenum 78mm 4.6L 2V 1996-2004

One of the keys to making horsepower is get as much air as possible into your engine. In the case of our 2002 Mustang GT, we've already removed the factory air intake and replaced with a JLT which gave us a nice bump. The next restriction is going to be factory throttle body and plenum. Today, we're going to remove the restrictive 2 piece set up and replace it with this 1 piece plenum from BBK.

The BBK's 1 piece design, the 78 millimeter opening is going to flow a lot more air than the factory set up. It comes with everything needed for installation including gaskets, new hardware, as well as 2 different PCV fittings. One to fit your '99 through '01. The other to fit your 2002 through 2004. For this installation, you're going to need a Phillips head screwdriver, a flathead screwdriver, a small flathead or pick, 3/8 ratchet, short extension, 8 millimeter socket, 10 millimeter deep socket, 4 millimeter Allen key, and a 5 millimeter Allen key.

The factory throttle body and plenum is located right here. The factory is a 2 piece design but we're going to remove it as a 1 piece, just like the BBK is going to install as a 1 piece set up. The first thing you're going to do is disconnect the battery since you're messing with some sensors, then we'll start disconnecting everything around the intake and plenum.

Disconnect the negative. We'll start the removal by taking off the EGR valve. Now we can remove the bracket for the throttle body and cruise cable. Once we have the bracket off, we can remove the spring and then the cable themselves. Push that aside. Next, we'll disconnect the throttle body plug as well as the idler control valve and remove the vacuum fitting. Remove the 2 hoses from the front as well. The last step here is to disconnect our JLT from the factory throttle body.

Now, we can unbolt the plenum from the intake. There are 5 bolts that hold this on. Lift it up. Disconnect the line in the back and put it aside. This lower gasket here is reusable, so take a quick look at it, make sure it's in good shape and it's clean. Now, we can begin our installation. Before we can install the BBK, there are a few pieces we have to transfer over from the old throttle body. We're going to remove the throttle position sensor as well as the idle air control and move them over.

Here you can see the huge difference, here you can see in size huge difference between the BBK and the stock throttle body. We mentioned in the beginning it comes with 2 PCV valves because Ford did make a change midway through the SN95 models. Just want to grab the size that matches the one that you have. The other one can be put aside. We'll install the auto air control, be sure to use a new gasket which is provided along with the new hardware.

Before you install the TPS sensor make sure you install a supplied bushing. That goes in first and then you can install the sensor. Again, BBK supplies new hardware for this. Then we're ready to install back on the Mustang. We'll start by getting the throttle body connected to our JLT. Now, we use the BBK supplied hardware to connect the throttle body plenum to our factory intake manifold. Once we get all four of them started we can tighten them down. Now we're going to reconnect all the plugs and hoses. Don't forget the one in the back.

Now grab the cable for our throttle and cruise control. Once you connect the cables, you're going to reinstall the bracket. The last step on the plenum is to reinstall the EGR with the new gasket. Reconnect your battery. The installation is finished. The plenum works out perfectly. It's settled into a nice idle. If it is idling high, you can adjust this screw right here, otherwise you're good to go. Our BBK throttle body and plenum along with the cold air kit should be good for a nice twenty to twenty-five horsepower bump on our GT. Installation will take you around an hour. You'll be back on the road in no time.