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I just pulled the 4.6 out of my '99 F150 and I'm thinking about putting a new lower intake on it. It has the aluminum upper and nylon lower on it right now. I'd rather have an all aluminum intake. It looks like the newer 4.6 truck intakes have a nylon upper and aluminum lower. Can I use that lower with my OE aluminum upper? The upper is the part that actually bolts to the heads, so it shouldn't matter what heads I have (PI or not). I found a new aluminum lower for a fair price, but not fair enough that I'd be OK buying it without knowing if it'll work. My issue with the old lower is that the plastic heat shield between the upper and lower is so deteriorated that I can crumble it in my fist and I honestly removed most of it from the valley with a vacuum. I'm concerned that the actual intake may not be far behind and it would REALLY suck having to pull the intake when it's back in the truck.
Also, where would be a good place to get a service/shop manual for that truck without spending a few hundred dollars? I don't mind if it's a digital copy. I already have the Chilton and Haynes books.
I ended up cleaning the original nylon intake. I soaked it in a parts washer for a few days, then spent hours washing it with engine decreased, scrubbing with a wire brush (attached to a long handle to get to all the hard-to-reach spots), and finished up by washing it in Dawn. I inspected it pretty thoroughly and it seems structurally sound, so I decided to re-use it. Sorry in advance to anyone else who was wondering if the aluminum lower and upper were compatible. Just check the return policy of whatever company you order the lower from. I'm pretty sure they're compatible.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.