Has anyone ever replaced the upper intake manifold on a Expy V8 5.4L. If so, on a scale of 1-10 what is the difficulty? Dealer wants 1800 big ones but the intake and gaskets only run about 250..

Thanks
Steve

 

There are several threads on here where people have replaced it. No one seems to have claimed it was difficult, to the best of my recollection. Try searching, I'm sure the threads won't be that hard to find.

 

Torque to spec on installation, and since you'll be that deep, replace the PCV and elbow. Also, if you are due for plugs, that would be a good time to do it, just cover all holes where parts and/or tools can fall.

 

Don't forget about the coolant tube between the upper and lower intakes that likes to leak.

 

Why are you replacing your upper intake manifold?

Shane

 

Speaking of intakes, mine failed yesterday. I have the standard passenger side intake crossover pipe leak. I initially had COPS fail back in December, but it wasn't obvious why. Six week ago I noticed coolant leaking along the rear of the engine dripping onto the ground. I did not see any obvious coolant in the engine valley. I topped off the coolant and drove home and looked for leaks. Low and behold, no leaks. I drove for another six weeks and then had a puddle again. This time it was obviously coming from the crossover intake manifold on the front passenger side. Since it was night, I read posts on this problem and started the removal and refit today.

I'm 4 hours in and probably another hour or so to get the manifold off. It is not particularly difficult, but it is time consuming because of all the parts that need to be removed and the limited clearance.

I still have several problems I need help on so far:

(1) How does the cruise control linkage come off the throttle?
(2) How do the injectors come off the fuel rail?
(3) Can I leave the fuel supply and return lines connected and just set the rails to the side?

Thanks for anyones help. I can easily see a dealer charging that for the repair given the hours involved and their current shop rates. Good luck with your leak.

 

Hey Quick35, I have a coolant leak just below the heater hose in the aluminum water outlet housing. There's a gasket there that has obviously gone bad but the housing is sold as one piece and is attached to the upper intake. It would be so simple if I could get that housing separated from the intake but again everything I've seen shows it as one piece even though you can see the 3 bolts that attach it to the manifold. 2 of them I can get to but the other I cannot.

 

I hear the same thing SIBCC, not too difficult but time consuming. I've been trying to locate a mechanic but with no luck. Looks like me and some buddies will be tackling this one ourselves.

 

Check out the posts by Steve (Ill). I kinda like his epoxy fibre gasket fix and may try it rather than buying a manifold. This assumes that my o-ring groove is blown out on the plastic manifold. I'll find out tomorrow when I pull the manifold. I think that this crossover design is fundamentally flawed. I know it has worked for 9 years, but it certainly isn't elegant engineering.

 

You did not mention what year and engine you have. If it is like the 98 5.4;
1. You pull straight up on the linkage where it pivots at the throttle body.
2. The injectors are just pushed up in with the o-rings holding them in place
3. You could but it would be much easier if you use a fuel line connection release tool and just get them completely out of the way.

 

2002 Ford 5.4 in an Expy

Removed the manifold. I found that the o-ring groove on the manifold piece sandwiched between the head and aluminum crossover tube had cracked allowing coolant leak.

Found spilled oil from oil fill tube along exterior of manifold.

Found the fiber/foam material in the sound deadening/ heat shield under than manifold was completely disintegrated. I'm thinking of leaving this shield out on the reinstall.

Cruise control cable simply snaps on and off. I asked because I did not want to break it.

I left the fuel rails in the vehicle.

I'm now going to change plugs and clean the gasket surfaces before installing the new manifold. Working slowly and taking pictures, I have about 5 hours into this so far. I inspected the plugs and they all looked good. They were changed about 8000 miles ago.

 

Finally got the manifold replaced! Took about 8 hrs but well worth the the $1500 bucks savings by doing it myself. She's prrrring again! Thanks for all the advice and info!

Sayala

 

That's $187.50 an hour you paid yourself to do the work. Your regular job will never feel the same again!

 

Same problem on my 2000 Expy with the 5.4l Triton. Hoped it was just an o ring blown out on the crossover, but it blew out because the Plastic groove was broken on the intake. Just wondering is the manifold a dealer only part? and of course how much?? Also mine appears to be all one assembly. Is there a lower and an upper? I've already got it out but cant seem to see any way of seperating.

 

Congrats on getting it done. Please post your pics.