I have a 2003 Expedition XLT with 205,000 miles and a leaky/broken coolant tube under the manifold. I had the plastic manifold replaced several years back to the tune of $1,500.00, and have replaced the coil packs & plugs myself.

I need to fix the tube, but In browsing this forum, I see threads for replacing the manifolds on 97-2002 expy's, various yr 5.4 F150's, but never a 5.4 2003-2006 expy. According to many threads, "if you are capable of replacing the spark plugs you should be able to remove the manifold"

With that in mind, can anybody give me a list of steps or point me to a video of removing the manifold for an '03 - '06 expy?
Thanks! wedo43

 

You can repair the leak without pulling the intake. Here is a video of the procedure.

 

I had a leak from the intake manifold, which I replaced myself. A fairly complicated (for me) job and could not have done it without a Ford shop DVD. The tube was OK. I still wrapped the tube in a slit rubber heater hose to prevent it from contacting the block and cracking.

 

Thanks for the reply Matt. I found this on ebay -
2002 - 2004 Ford Car Truck Service Manual DVD Includes Powerstroke mustang F150

Is this the Ford Shop DVD Manual you speak of, or is there a DVD that focuses directly on the problems/repairs to the coolant manifold?
Thanks, Wedo43

 

I obtained a Ford Service DVD from the dealer. It's expired as the dealer would get a new edit monthly. This was back in 2004. I don't think they do it that way any more. The DVD covers all 2003 passenger vehicles