So after tons of work and $$$ I realized that the intake generator/fan mount guide (in red) is half missing. I have two other intakes and they both also have the same cracked guide. I have this crazy idea to drill and tap through the generator mount to have to bolts go through until they sit in the intake slots (yellow). I figured if the rest of the intake guide breaks, the bolts will hold it in place. Anyone come up with a creative way to resolve this besides find another intake? Or maybe welded on a new guide to the intake (cast iron)?

 

I bet half the flatties on the road are like that. Just make sure your big nut is tight after adjusting. If it really bothers you, I have some manifolds that aren't broken. Email me if interested.
https://www.ford-trucks.com/forums/1...ated-list.html

 

Makes sense considering that the 3 intakes I have are all broken in the same spot :-) Well, I think I will go with the existing intake but as soon as the fan and gen go through the radiator, I will contact you and see if you still have those intakes laying around :-)

 

Educate me. So what causes this? The nut not being tightened properly.

 

Maybe the nut behind the wheel is loose!

 

Good point ..check out my belt tension adjustment tool. Now Im a novice but looking at the chip on all 3 intakes, it appears it is due to applying to much pressure at an angle and not having seated correctly against the guides, when adjusting the tension.

 

It also happens if you loosen the big nut and just let the yoke fall down.

PS -- that's absolutely the best way to tighten it!

 

I have an unbroken intake that I am not using. PM me if you are interested.

 

Thank you and I might take you up on it once I find out if my "great idea" will work. I will be drilling and tapping the generator bracket, so that I can thread bolts through the bracket and sit in the intake slots, which should still allow the bracket to adjust up an down as well as secure it from turning. Of course if it doesnt work I will reach out

 

Don't the fan bolts do that already?

 

Interestingly enough thats the first thing I checked when I realized the intake guide was broken. My generator bracket existing bolt holes do not align directly into the slots. They are partially blocked by the intake, to wide. Thats what gave me the idea to drill new ones closer to the center of the bracket that would clear and into the slots. Im pretty certain my gen bracket is for the truck intake (RT). Do your bolts fit into the slots?

 

I always assumed the two slots were aligned with the fan bolts, but never checked. If they weren't it seems like the bolts could bottom before tight.

What about making a replacement for the big washer, that is a washer that extends down and has a peg that rides in the slot in the center?

 

So this is my creation but with a help of a local machine shop. I had them center tap and thread holes so they align with the slots on the intake. This is just in case the intake guide finishes breaking off.

 

Don't those interfere with the fan mount?

 

No, they are sunken in so the fan mount can slide up and down to adjust belt tension.

Im still puzzled that the original bolt holes on both my gen mount do not align with the slots on my 3 intakes. It just seems they should and accomplish what I just did.