I've got a 98' explorer, and there was a weird noise coming from the engine, it sounded like a loose rocker arm or something, It always made the noise when it was cold outside. Anyway, I took it to the shop and they said it was the Intake Manifold, they replace it for $1400. I picked it up from the shop and it still made the same noise. I took it back and let the mechanic ride with me but there was no noise. He said that he had to replace 12 intakes this year on these newer explorers? Has anyone else had any problems with em. He said they might recall em back, but who knows?

 

Which engine do you have in your Exploder? I've never seen an intake need replacing. Lots of gaskets yes but not the whole intake.
How long does the sound last? Is it just when you first fire it up?
If you have the 4.0 SOHC check out the thread on this page called "clicking noise when truck fires up".

 

the noise only happens for about 20 min after startup. Dont know what it is, but thats what i took it in for and they said that the upper and lower intake needed to be replaced. Its a 4.0L V6 but i feel like those people just lied to me