New instake manifold?
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Freshman User
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New instake manifold?
Hello everyone,
I think that my intake manifold gasket is leaking. I tested it with carb cleaner. This is a 2001 car with 200,000 miles on the clock and it is still on the original intake manifold. The question is: given that it is an old manifold is it worth replacing it for a new one now that I am doing the tear-down?
I understand these plastic manifolds just age and eventually crack. Am I correct?
Any suggestions will be appreciated.
Thanks
I think that my intake manifold gasket is leaking. I tested it with carb cleaner. This is a 2001 car with 200,000 miles on the clock and it is still on the original intake manifold. The question is: given that it is an old manifold is it worth replacing it for a new one now that I am doing the tear-down?
I understand these plastic manifolds just age and eventually crack. Am I correct?
Any suggestions will be appreciated.
Thanks
Junior User
Joined: Oct 2016
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yes i have heard they crack and yea it's worth it to change it out if you got the money to do so.my luck id reuse it and have issues later down the road, get one with the aluminium cross over that's in the front.i bought my 99 5.4 and it has an all aluminium intake manifold 
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Freshman User
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yes i have heard they crack and yea it's worth it to change it out if you got the money to do so.my luck id reuse it and have issues later down the road, get one with the aluminium cross over that's in the front.i bought my 99 5.4 and it has an all aluminium intake manifold
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factory, but you will have to relocate some coolant hoses. I just can't remember which one?
Posting Guru
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The 1st gen had aluminum on 4.6 at least, but perhaps plastic on the 5.4? I know in the 1st gen and "phase 1" '03 and '04 2nd gen they had plastic intakes with aluminum crossover, but not sure if perhaps earlier 1st gens had full aluminum intakes, or if that was only on the 4.6 or what. I do have a friend with a '99 4.6 Expy which I know has a full aluminum intake.
Anyway, what was common in the plastic ones with aluminum crossover was that it would crack where the aluminum crossover connected with the plastic intake. In the '05 they changed this, and made the aluminum crossover a separate part and the intake pure plastic, which has for the most part cured the cracking issue.
Anyway, what was common in the plastic ones with aluminum crossover was that it would crack where the aluminum crossover connected with the plastic intake. In the '05 they changed this, and made the aluminum crossover a separate part and the intake pure plastic, which has for the most part cured the cracking issue.
Junior User
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How would i be able to know for sure it's factory or aftermarket ? easy way ?looks factory to me and my heater hoses are towards the back of it. i don't remember seeing any towards the front while i was changing the alternator but DID see some black plastic box looking thing under neat the intake ???? there were flat black plastic/abs pieces broke off just laying down in there i dug em all out and threw away maybe a heat shield ??
Senior User
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From: Littleton, CO
As best as I can tell this is my factory intake. See the aluminum coolant crossover?
Here's where they fail. See the crack in the upper window:
This is the Dorman recommended replacement:
Here's where they fail. See the crack in the upper window:
This is the Dorman recommended replacement:
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Posting Guru
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Yep, that's a typical failure point in these intakes. The newer ones on the 3v engine solved this issue by separating these two pieces.
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Junior User
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So now it's got me curious if mine is stock or just upgraded or a different year of engine since i keep reading about the plastic intakes issues on 99's mine being aluminium mines Expo is a 99 sure it's nothing special
whats the black box looking thing under there ?? lower intake plastic but upper one aluminium seems weird if you ask me
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Thanks for all the replies. I tried to find an all aluminum manifold to replace mine with but I could not find anything for the 5.4L. All the ones I found were plastic with aluminum crossover. I guess I have no other choice but to replace it with a new Dorman unit.
Once again. Thank you very much.
Once again. Thank you very much.
Posting Guru
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That plastic box underneath is the lower part of the intake plenum. In the early models the intake plenum was separate, so the intake consisted of two parts, the upper part and the lower part with a gasket between. In the 3v, this is now only one part.
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I think even if the upper and lower is plastic, you can still separate them. They do sell a gasket which fits between the upper and lower plenum, so that leads me to think it's two pieces. When buying a new intake, I think they sell the upper and lower as an assembly, not separately, so you rarely ever have to separate them. I guess the only times would be if you're gonna replace the gasket, or perhaps for cleaning purposes, though since they changed the design on the 3v to a one-piece design, I guess it wasn't really needed to have them as two pieces.
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