Hi everyone, I have been reading this forum lately and finally have a problem that I can't find a previous post on. I have a 1988 F-150 EFI 4.9L 6 that had some problems (details below) and I now have an ear broken off of the lower intake. It is the rear-most bolt hole that broke off. The entire ear is off, the break does not go through the bolt hole. My question to the more knowledgeable is: Can this be welded up and the face machined or should I replace it?

History
I bought this truck new in late 1988 (my first new vehicle) and it has served me well all of these years with only the most minor of problems. My father recently borrowed it for a few months as he was without a vehicle and he noticed a water leak from the water pump . He took it to a local mechanic and the water pump was replaced, two days later on his way home from shopping (groceries are 30 miles away) the radiator drain plug went missing. The engine died at a stop sign some time later (dad didn't notice the temp), obviously overheated and not running well anymore. The diagnoses was problems in the lower end.

I brought my truck home and eventually decided I could not part with it so easily. I pulled the engine and was in the process of rebuilding it as per my ebayed Haynes manual. When I pulled the last bolt on the rear exhaust/intake manifold, the lower intake came off in two pieces. I suspect that I should have loosened the bolts all a bit at a time, the break is clean and appears to be new.

So, what are my options? I saw a new lower intake somewhere online for upwards of $500 is that my best option?

I want to say thanks to all of the regular contributors here, this is an absolutely indispensable resource. I would not have attempted this project had there not been such a great amount of information available.

 

You can take it into a fab shop that is good with aluminium, possibly one that builds trailers, flatdecks etc. and see what they can do but it may be just as easy to check the wreckers for a used intake.

 

I've seen lowers and uppers on ebay for $75 each. But any welding shop with a TIG welder should be able to fix it. But the intake really doesn't need to hold pressure so even JB Weld would work.

 

Agreed, the ear could easily be welded back on, and the intake planed to insure it's flat.
One of the regulars here went thru this same type ordeal on his aftermarket 4 bbl intake. Got it welded/planed, and it has been working fine since.

 

I think the shop charged me $60.

Just be sure to find one that deals with aluminum.

 

Was your ears burning AB? LOL.

 

Heh, they were.

"Someone out there needs a picture!"

 

The break on my manifold is in the same place as in that picture. Thanks for all the help!

 

Not an unheard of scenario. It's been mentioned several times in the past on this Forum.