Hi guys,

I am trying to source a used intake plenum for my 2004 11/03 build (square egr cooler).

I found a few on ebay and they look identical to what I have now. One guy is telling me it will not work and one other guy is telling me yes it will work. The manifold looks identical to what I have now but the casting numbers are different.

Who the hell do I believe?

Can anyone confirm that the manifolds for the 2004-2007 are the same and compatible please? The 2003's had the oddbal manifold with the casting in the back and the older round cooler. Mine was square from day one as these newer manifolds use.

Thanks
Joe

 

Older intakes had the crossover in the back, it makes removing the turbo manditory if you need intake work. Square or round EGR cooler doesn't matter, the round ones were better built.

What I know.

 

So I got to the bottom of my conuundrum. I talked to BPD and they confirmed that the u-shaped intake plenum with the square cooler is compatible with all years that utilized the square cooler (2004-2007).

The early 2003's have the boxed in intake manifold with the round cooler.

Incase someone runs into the same dilemma, there's your answer

Thanks
Joe

 

Ahhhhh.......but wait. Late 2004 model years also use an EGR throttle plate, while 2005 and up model years DON'T. That said, there are dimensional differences where the intake "elbow" bolts up.

Look at page 7 of this:

http://www.forddoctorsdts.com/filebi...eTableBook.jpg

 

Understood. I cross referenced the casting numbers on the top of my manifold and the one I bought, they both have the same casting numbers 1840658C3 .I removed my throttle plate years ago ( the butterfly) if that's what you are referring to. What do you think mchan?

 

I've had all three on my truck at one point or another. The 03 requires the round EGR cooler. The 04 and up either require the throttle body plate and a short elbow or a long elbow without the throttle body section and a square EGR cooler. Regardless, they'll all work on your motor. What's wrong with the one you have now?

 

Well Tim I messed up long ago and bought a fcdp egr delete before the smog laws hit , where the plenum is modified for coolant reroute making it an egr delete. I sent mine in as a core.

I am in the process of compiling parts to do the bpd oil cooler and egr cooler setup and return it to smog legal status. Laws are getting stringent in ca and since I am tearing the top off again for the bpd stuff I figure might as well do it now. Nothing worse than getting caught..... Possibly a fine and/or having to go to a DMV referee station.

I wish I could sell the fcdp manifold it really is a top notch egr delete.

 

Nccpartsman...... Pm sent

 

Anybody want to buy a nice EGR cooler delete? Mine still has the egr hole open but the valve was turned off with my tuner. It is a solid kit and at this point I cannot use it anymore.