I'll try and get some pics up but I didn't mention before the car was on a scanner when the MIL light came on for the error codes and went into diagnostics and the TPS was correctly identifying C/T, P/T and WOT. The reference voltage was also correct, around 0.5V at idle and 4.6V at WOT which is about right. The throttle body is made particularly for the focus zetec engine 1.8 and 2.0 which are both in essence exactly the same engine bar the displacement and a few other things. same head, throttle body, inlet etc etc.

Because of the correctly identified positions of c/t, p/t and WOT I am assuming its just the TPS needs changing but I do have a slight doubt that it cannot see the full range of travel that is why it is throwing up out of range since the TB will not allow it to be mounted properly, in which case the 65mm TB is coming off.