I was topping off the windshield washer fluid and noticed a damp grimy area. I think it looks like a coolant leak. Thoughts? Any one having instructions for tearing this down to replace the gaskets?
Front passenger side intake crossover. There was a decent build up grime I wiped with my fingers. It didn't smell like anything.
It's moist down in the valley area.

 

Anywhere near the oil fill port?

 

It's near the fill port, but the valve cover is completely dry around the fill port.

 

Hey bronco, mine pretty much looked the same when I had to replace a cracked intake gasket. I checked YouTube and believe the attached link is what I referred to. Pretty straight forward and I think it took me 2-4 hours. Also, get an intake gasket set similar to the link....See below.....

After you remove the intake, cover the intake ports on the engine, inspect the knock sensor wire for cracking and fraying and replace if necessary (I had to remove it again after I got the knock sensor code...Grrr) Also inspect the water tube on top of the engine.

More Information for FEL-PRO MS98008T3

 

Thanks for the video, pretty helpful. That guy had another video about 5 minutes long that shows taking off the aluminum crossover tube to inspect the intake mating surface and replace the gaskets. I think this is where the fluid is seeping from on mine. Now I'm a little worried I have a cracked intake like the one in the video.

 

You just reminded me, that is what I had go wrong. The first time I had to replace the intake because it was cracked in that area. Months later I got a solid knock sensor code because the wires were bare and touching at the connector requiring a new knock sensor, so I had to replace the knock sensor which required the intake removal and another set of gaskets. That's why I said to inspect everything after intake removal.

 

Where is the knock sensor located? I don't recall it being pointed out in the video.

 

On top of the engine directly under the intake. The wire runs back towards the firewall and connects in the area behind the intake surface above the rear injector. My wire was stripped bare at the connector. I have a 2000, I think the 2003 is the same.

 

There's actually 2 of them on certain years and models. This image is supposedly of a 2003 Navigator.

 

New development, got a Bank 1 Lean code. It still runs fine, no missing. So I'm interpreting this as a high probability of a cracked intake (and not just a bad gasket on the water passage) and I'm getting a little coolant in cylinder 1.

 

Wow! I am a little late to the party, but this is great info! Great pics! Great vid! Thank you!

My 2003 Ford Expedition EB 5.4L V8 - 4X4... I'm the only owner and I am very proactive with maintenance if borderline compulsive.... No symptoms nor engine dashboard lights yet.
But when I had my Expedition in to my ONE trusted master seal tech at my local Firestone to resolve a Service Engine Soon light - that one was a cracked vacuum line and needed a new EGR valve - he suggested that I might consider replacing the entire intake manifold and its gaskets soon.

When he called to report his initial diagnosis for the SES light recommending the EGR valve, then a few hours later after replacement, he then made this recommendation for intake manifold and gaskets I believe because he said he saw some smoke leakage on a follow-up smoke test, after replacing the EGR valve and small vac hose. He did say the vehicle was completely safe to drive with the existing manifold/gasket and did not mention any coolant leaks.

I am now going to use the pics in this thread to look for coolant leaks.

Todd

 

I guess FYI for the rest of the world... the intake finally sprung a leak summer 2020 at 150k miles. Typical delamination.

Gasket plastic cracked.

 

Did you already complete the repair ? If you need an OEM intake, they're still available in old stock.

New Ford 2L1Z-9424-AA Intake Manifold Assembly on eBay






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Thanks Ham. I did the repair last summer when it finally let loose. I ordered a genuine Motorcraft intake from Lakeland Ford. I don't trust ebay to sell genuine Ford parts. Lakeland Ford has better prices than my local dealers and they're so close I get in stock parts in a day or 2.

 

Oh ok. I didn't notice you were in Melbourne. Yeah Lakeland Ford is a good source for us too. Great that you got it done.