Go Back   Ford Truck Enthusiasts Forums > Newer Light Duty Trucks > 1997 - 2003 F150
Sign in using an external account
Register Forgot Password?


1997 - 2003 F150 1997-2003 F150, 1997-1999 F250LD, 7700 & 2004 F150 Heritage SPONSORED BY:

Welcome to Ford-Trucks Forums!
Welcome to Ford-Trucks.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the Ford-Trucks Forums community today!





 
     
Old 11-21-2014, 07:46 PM
How-Tos on this Topic
 
Last edit by: IB Advertising
See related guides and technical advice from our community experts:

Browse all: Air Intake and Exhaust Guides
Print Wikipost

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
  #16  
Old 09-29-2010, 12:25 PM
maddan5.4 maddan5.4 is offline
New User
 
Join Date: Sep 2010
Posts: 4
maddan5.4 is starting off with a positive reputation.
removal and repair of intake manifold on 5.4L

Following up on previous repair of coolant leak at crossover-intake manifold interface, I too now see that the plastic manifold housing has bulged out and cracked. I would like to try RTV fill and regular gasket rather than replacing entire manifold. Should I snap off the bulging, cracked plastic piece? Alternatively, should I fill within the entire encircling groove and behind the cracked portion. Any advice greatly appreciated.
Reply With Quote
  #17  
Old 12-24-2010, 04:35 PM
rguerra rguerra is offline
New User
 
Join Date: Dec 2010
Location: Edinburg
Posts: 1
rguerra is starting off with a positive reputation.
I just took off my intake manifold on my 1999 5.4 f150. Two of my intake ports were not black and oily as the rest, they were clean and rusty. Does that indicate that indeed I need to replace my head gaskets? Thanks in advance.
Reply With Quote
  #18  
Old 01-14-2011, 11:55 AM
Knuckle47 Knuckle47 is offline
New User
 
Join Date: Jan 2011
Posts: 5
Knuckle47 is starting off with a positive reputation.
So here it is, the coldest week we have had and I am going to have to do this same job OUTSIDE ? This terrific post explains the exact problem I am having and not looking forward to it. Other than this, my truck runs so well...You could not tell the difference in its run or start abilities from the day it was new...now 10 years ago ! I've just gotta fix it

Thanks for the great information
Reply With Quote
  #19  
Old 01-14-2011, 02:53 PM
Knuckle47 Knuckle47 is offline
New User
 
Join Date: Jan 2011
Posts: 5
Knuckle47 is starting off with a positive reputation.
Is there any list of gaskets and o-rings I may need once I am into this project. It appears the weekends are the only option and of course the dealers are closed. It would be nice to have everything in advance....Thank you for the help....AL
Reply With Quote
  #20  
Old 01-14-2011, 11:31 PM
steve(ill)'s Avatar
steve(ill) steve(ill) is offline
Post Fiend
 
Join Date: Jul 2005
Posts: 6,262
steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.
i went to auto zone and bought the manifold gaskets. I think you only get two gaskets and they cost $40-50. for the pair. THE cross over needed two o-ring type gaskets, but my o-ring grooves were destroyed. I had to fill the groove with epoxy, file smooth and use RTV and paper type gasket like you did in the 70s. THe o-rings did not come with the manifold gskets. The two manifold gaskets is all i used.
__________________
2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
2001 SuperCrew 4 x 4 5.4 XLT -235K miles -GONE
Reply With Quote
  #21  
Old 01-15-2011, 12:34 AM
Racerguy's Avatar
Racerguy Racerguy is offline
Super Moderator
 
Join Date: Aug 2002
Location: BC, Canada
Posts: 12,667
Racerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to beholdRacerguy is a splendid one to behold
Just a little hint that may save somebody some grief ......
As soon as you get the intake manifold off it's a good idea to stuff paper towel or rags into the intake ports so nothing can fall into them.
I also always check each port before putting the intake on to make sure nothing has fallen into it.
I've seen engines destroyed when this happened.
__________________
Dave - FTE moderator
Forum Guidelines
this space for rent
Reply With Quote
  #22  
Old 01-15-2011, 09:48 AM
steve(ill)'s Avatar
steve(ill) steve(ill) is offline
Post Fiend
 
Join Date: Jul 2005
Posts: 6,262
steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.
yes, Racer is right. I actually have two small plywood strips with a couple boltl holes in each to hold them in place where the gasket sets. covers all the ports. When you wire brush or clean the gasket face, do it one at a time and double check nothing goes into the holes !
__________________
2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
2001 SuperCrew 4 x 4 5.4 XLT -235K miles -GONE
Reply With Quote
  #23  
Old 01-15-2011, 11:01 AM
Knuckle47 Knuckle47 is offline
New User
 
Join Date: Jan 2011
Posts: 5
Knuckle47 is starting off with a positive reputation.
Thanks for the information guys...The engine has 242,000 mi and has shown no signs of giving up other than an occasion #2 coil issue. Of course, this may be why. I 'd hate to see the truck go so aside from the replacement dollars I don't have, I am best to fix the problem. I was un aware that Auto zone has these parts...I am on my way. Just wish it would get above 32 degrees for a day or so
Reply With Quote
  #24  
Old 01-25-2011, 12:18 PM
thumper477 thumper477 is offline
Junior User
 
Join Date: Dec 2009
Posts: 53
thumper477 is starting off with a positive reputation.
I just bought a new manifold kit for my '00 expedition 5.4 with gaskets,thermostat,and of course a new manifold from amazon.com.It was a Dorman brand and it was 160.00,shipped free-no tax.Came in 4 days ups.I am taking it apart and I need any tricks as to how to get the manifold bolts out without snapping them off in the heads.Any tricks?
Reply With Quote
  #25  
Old 01-25-2011, 11:13 PM
steve(ill)'s Avatar
steve(ill) steve(ill) is offline
Post Fiend
 
Join Date: Jul 2005
Posts: 6,262
steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.
intake manifold bolts are clean and should come right out no problme. THE exhaust manifold bolts take a beating and sometime come out tough or break.... I had no problems at all with intakes.
__________________
2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
2001 SuperCrew 4 x 4 5.4 XLT -235K miles -GONE
Reply With Quote
  #26  
Old 02-03-2011, 07:51 AM
vbevans vbevans is offline
New User
 
Join Date: Sep 2010
Posts: 3
vbevans is starting off with a positive reputation.
Thanks so much for this article, but especially for the idea to fill the o-ring groove and install a flat gasket. I'm not sure I would have thought of that myself. After seeing this wonderfully engineered failure point for myself, I shouldn't be surprised if many owners face this repair. Only other option would be manifold replacement $$$$
Reply With Quote
  #27  
Old 05-10-2011, 06:34 PM
jhammer30 jhammer30 is offline
New User
 
Join Date: May 2011
Posts: 3
jhammer30 is starting off with a positive reputation.
Steve... what did you use to fill in the o-ring groove? Is it still holding up?
Reply With Quote
  #28  
Old 05-10-2011, 06:55 PM
steve(ill)'s Avatar
steve(ill) steve(ill) is offline
Post Fiend
 
Join Date: Jul 2005
Posts: 6,262
steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.
I had considered using something like liquid steel or JB weld.. but finally decided on a two part expoxy glue. YOu mix parts A and B in equal amounts. I bought it at Menards lumber yard i think.. I was like two 4 oz bottles, not tubes. I thought the epoxy would be closer in material properties to the plastic manifold than the JB weld type stuff.. I used a small die grinder to roughen up the groove inside and clean out any broken parts. I took duct tape and made a "dam" around the ID and OD of that port and poured the expoxy in till it came up over the final level i wanted by 1/32 inch. LEt it set a day and dry, then filed it flat with a big file. Make sure you get it flat and dont roll off the edges. I made my own gaskets from "gasket material" i bought at Auto Zone, just like the old thermostat gasket material. Put a little permatex or RTV on the gasket as sealer just like you did 20 years ago before all these o-ring seals became standard.
__________________
2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
2001 SuperCrew 4 x 4 5.4 XLT -235K miles -GONE
Reply With Quote
  #29  
Old 05-10-2011, 06:59 PM
steve(ill)'s Avatar
steve(ill) steve(ill) is offline
Post Fiend
 
Join Date: Jul 2005
Posts: 6,262
steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.steve(ill) has a good reputation on FTE.
yea its been 19-20 months since the repairs. Probably 25-30k miles and all is well.
__________________
2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
2001 SuperCrew 4 x 4 5.4 XLT -235K miles -GONE
Reply With Quote
  #30  
Old 05-10-2011, 10:48 PM
jhammer30 jhammer30 is offline
New User
 
Join Date: May 2011
Posts: 3
jhammer30 is starting off with a positive reputation.
Thanks for the detail, it looks like I will have to repair both the right side and the left side around the thermostat. The left side was not leaking but the o-ring slot is starting to crack just like the other side. I have heard of this old-timey make your own paper gasket myth but have not done it myself. We'll see how it works. lol.
Reply With Quote
Old 05-10-2011, 10:48 PM
 
 
 
Reply

Similar Threads
Thread Thread Starter Forum Replies Last Post
1997 Explorer P0171 & P0174 OBDII Codes 04FordHarleyF250 Explorer, Sport Trac, Mountaineer & Aviator 7 01-07-2013 11:49 AM
Cheap rocker panel repairs steve(ill) 1997 - 2003 F150 0 11-12-2012 08:49 PM
Coolant Leak vbevans 1997 - 2003 F150 0 01-24-2011 05:23 PM
Replacing intake manifold on a 5.4 Superdave Modular V8 (4.6L, 5.4L) 6 03-03-2010 04:10 AM
Intake elbow gasket / o-ring part number Skweeker 6.0L Power Stroke Diesel 6 10-20-2005 05:59 PM


Go Back   Ford Truck Enthusiasts Forums > Newer Light Duty Trucks > 1997 - 2003 F150

Tags
150, 2005, 54, 54l, air, f150, ford, intake, leaks, manifold, motor, removal, remove, truck, water

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump



All times are GMT -5. The time now is 11:18 PM.


Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. FordŽ is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup