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I bought the TB butterfly valve shafts replacements from Beemer Boneyard a while back and now getting around to putting them in. I was reading the repair manual, Haynes I think, and it talks about removing the tank and other steps to remove the TB. While now difficult, I really get tired of removing this tank. It's that necessary or can I remove the TB by just undoing the bits holding it on. It's 24 degrees out right now so I haven't wandered out to the shed to look at it closely yet.

Perfect. Thanks

removing the tank for TB's? nope. pretty straightforward. that vid is fantastic.

So, I removed the right side TB. Took forever to remove the cap but finally got it off by applying heat and working at it. Now, I am completely stuck on the bushing removal. I had a 3/8" tap but that didn't work. Probably too big. I have tried a piece of solid copper wire but probably have too large a gauge to get a good bite. I ordered a 8mm and 9mm tap to see if that works. Any other guidance on this? I knew this would be a bigger pain in the butt than the instructions let on but great googly moogly.

You could try a lag screw but do not thread it in really tight because you do not want to expand that bushing. Not sure how close to the inside diameter of the bushing the housing of the throttle body is but if it is larger ID than the bushing you could even run a drill down the center to 'thin' the bushing wall down and then lightly tap it with a small chisel if the 'tap' method shown in the video does not work. Easy outs (something of a misnomer in my previous automotive experience) might also be another option.

So, the 8mm tap fit well and had good bite. Would not stick enough to get it to come out. Same result with the 9mm. Going to take the dremel to it and see what I can do. This is making me not want to do maintenance anymore.