well those friggin screws really pissed me off...
I got it done yesterday, well almost. I have to try to line up the butterflies a little better in their bores so they don't bind at all and tighten the screws. I might have to take the shaft out again and open the slot some more.
It was a time consuming ordeal. Those screws are a PITA, i don't think they are hardened at all. Every one of them broke in the 5.2 tb I originally planned on using. Luckily the v6 shaft I bought didn't give me any trouble, but the new 5.9 tb I scooped snapped one off, and the only way you're getting the butterfly out with a fastener that small is by drilling the screw right out.
The screws were giving me all kinds of problems going back into the v6 shaft. The friggin threads self destruct and go round when you take them out. I had to run an 8-32 tap through the junk shaft and run the screws I wanted to use through the hole to fix them. Then I ran the tap through the holes on the v6 shaft. This might not even be the right size, it might be some metric size but my screws were compromised and that was the tap in my toolbox that worked on my test specimen so it got the nod. They fit pretty tightly. I put some purple loctite on too. It's stupid screws like this that can ruin an engine.
Also, after hack-sawing the slots larger, I had to hit them with my dremel and a thin cutting wheel to open them up wider. My hacksaw blade didn't open them quite enough. This turned out to be a bit of a frustrating ordeal for me, mainly because of the screw problems. I am justifying this work by telling myself if my little 3.9 can't handle this much throttle body, the v6 one is a direct swap back on. I had more friggin fun then anyone else on here apparently replacing that v6 throttle cable after a freak arc out incident already I never want to do it again.