Intake manifold options?

[10K plus]

HI everyone i'm a first timer. I have done alot of reading on the intake manifolds and gaskets being weak on the 4.2 and that the 3.8s are mechanically the same block? I see some Thunderbirds, cougars have Aluminum Intakes (Most likely aftermarket) opposed to the plastics on the trucks and windstars? Am I wrong in looking into this any further?

I am getting a replacement block as it is seized most likely from the wonderful lower intake gasket problem that has plagued many on this site already. and since the engines already apart I am looking to do upgrades so it won't happen again.

Input would be welcomed ant thanks for reading - Mike From Calgary

[BrianA]

Hey Mike, Nice to have you here at FTE! Glad you found us and hope you stick around.

The OEM aluminum intake uses the Intake Manifold Runner Control setup (IMRC) so there is more involved if you wind up using one of those.

I am not sure if the newer (plastic) equipped engines manitained all the support systems that would allow for trying to use an old manifold on a newer long block.

To be honest, I am not sure what differences might disallow the use of one intake or the other.

I'd guess the plastic would be more likely to present fewer problems since the IMRC is not involved.

Also, all aluminum intakes used a manual throttle body. I believe there were a few years when the plastic intake manitained the manual throttle body, but all 2005 and newer engines use an electronic throttle body (no throttle cable).

As far as reliability, I've never heard of many problems with either.
I put 170,000 miles on a 2000, and have 121,000 on a 2005.
The gasket leaked at 155,000 on the 2000. But I have never had a problem with just the intake manifold on either.

Hope this helps some and please come back with more questions if you have them.

We'll help best we can!

[fordkev]

i work on alot of these and from what i've seen the ones with the plastic intake still use the same aluminum lower intake which is where the gasket problem happens so i dont think you,d gain anything by using the older intake

fordkev

[10K plus]

hey thanks guys its just the info I needed. Just priced out my shortblock today and hopefully going to get the truck rolling again. thanks