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1968-Present E-Series Van/Cutaway/Chassis Econolines. E150, E250, E350, E450 and E550

1999 E-150 Upper Engine Intake Manifold mysterious missing chunk?

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Old Mar 8, 2016 | 08:30 PM
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dbbldz
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1999 E-150 Upper Engine Intake Manifold mysterious missing chunk?

In my mission to get get my E-150 to pass emissions I noticed that there's a huge chunk missing out of the upper engine intake manifold. I'm fairly certain this is the source of my vans problems: horrible exhaust smell in the cab, **** poor gas mileage, weak acceleration, trouble shifting into higher gears, various shaking, etc.

Computer is throwing codes for misfires in two cylinders, running lean, and Turbine Speed Sensor not giving a signal. Which makes sense....

One question I have is... what in the actual heck hppened here???





Did the manifold warp somehow? Or did a piece of it actually break off somehow? If it did break off it's a pretty clean break but you can almost make out a jagged edge that's been smoothed out overtime. Bought this van a few months back and didn't notice this but I'm assuming it's had this problem for quite some time. What kinds of problems could this have led to overtime? What else might need to be replaced as a result?

Anyone ever replace the intake manifold on an older Ford van? How did it go?

p.s. it's the base V8 5.4L
 
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Old Mar 9, 2016 | 05:38 AM
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Im50fast
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From: Central Florida
Passenger side at the rear?

It's normal. We all talked about it in a previous thread. Everyone has that.

It's a hole to nowhere.
 
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Old Mar 9, 2016 | 12:25 PM
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dbbldz
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Ah!!!! Ok thanks!!! That's somewhat of a relief since I thought for sure the whole thing would require replacing. But on the other hand... I still don't know what's causing my problems... on the front end of the passenger side intake there was a section that was leaking coolant where the upper manifold meets the lower (epoxied first, then bypassed the heater core) so the gaskets probably need to be replaced at the very least.
 
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