Changed the intake on my 01 Screw 5.4 with the Dorman intake. It has a nipple in the coolant crossover, that must be used for some other 5.4 application. Anyway when I got it I found out the cap that was on the nipple was cracked allowing coolant to leak out new right out of the box.

Replaced that with a similar sized vacuum cap and now after 2 months and 4,000 miles (drove to New Mexico and back in that time) that one cracked and l just replaced it again with another vacuum cap from the package I bought before.

I'm looking for a more permanent fix. Anyone run into the this issue on the new Dormans?

I tried a search but couldn't find anything.

 

Did you find a solution? I installed the intake 2 months ago and tonight I found that cap cracked. Tomorrow, I plan to clean up the mess by vacuuming out the plugs holes and the V between the banks. I'm thinking about using fuel line with a bolt in one end and two worm drive clamps. I have not really looked closely at that nipple yet. The original cap seemed quite cheap because I did remember making a mental note of it. If you have any suggestions or solutions thanks in advance.

 

Might try contacting Dorman thru their website. Maybe they have an upgraded cap.

 

Nothing yet. I just emailed Dorman, as of right now I wish I would have ponyed up the extra bucks for the OEM intake if I am going to have to replace caps every 2 months

I am thinking I may weld it closed or try to tap it for a set screw. But it's ridiculous to have to do that on a $300 intake.

 

I agree. I don't know what application would even use the nipple.

 

Got an email back this morning, they have a plug and heavier cap kit they are going to send me. They also suggested removing the nipple and tapping the hole for a plug as another option. I'm having them send me the kit for now.

 

I have heard this once before at the parts store, if that kit has a part number could you post it up please?

 

Sure, no problem

 

I got the kit today. Its a plug, screw, clamp and cap. There is no part number but the instructions say "Ford 5.4L 2v Intake manifold coolant plug kit".

Looks like it should work good. The plug goes in the nipple 2mm below the top, then the screw screws into the top of the nipple to hold it in, and the cap goes over the top and is held on with the included clamp.

 

hi there vista461! i'm having the same problem with my truck 01 5.4l super crew, i try contacting Dorman thru their website trying to get the "Ford 5.4L 2v Intake manifold coolant plug kit". that you had mention before but they said that they don't show that listing for my application? and i can find nothing on their website ether so i was wandering if you can tell me how did you explain it to those guys because they see NOT to understand every time i email them, thanks.

 

I don't have my email anymore, If I remember right I just sent them an email through their site complaining about the leak and saying I would've gone OEM if I had known I was going to have to replace the plug every few months. I got an email back from an engineer who is the one that told me about the part kit and sent it out to me. Sorry I couldn't be of more help.

 

That's OK thanks any way I'll keep asking them.

 

Just put the "improved" doorman on personal truck 3 weeks ago...with the plug threaded already...the kit came with new T-stat, new nipple, & the nip.cap clamp etc. Plus, two more nipples...go figure...I had bought a complete intake from a 06' F350 that was all aluminum....just wanting the crossover itself since it's the same...albeit it was on a V10, the crossover is same w/xception of those nipples...well the intake finally let go catastrophicly before that came in...thus the whole doorman kit...& you also have valley space which cools better & give access to chts/pumphose etc. without having to remove intake again...not big on non factory parts, but WAY better than putting in another w/ same deign flaws...well worth the modest $300 w/ lifetime warrenty..IMHO