I have a nice pool of coolant on top of the block underneath the upper intake, which is either being supplied by a leaky crossover on the intake or a leaky heater tube that runs under the intake. Either way, I'm looking at replacing the intake, water pump, and whatever other parts are recommended to be replaced as a part of this project.

I see lots of negative feedback on the Dorman intake. My question is: Has Dorman improved the design recently to the point that it's an acceptable solution? Or, are there any other lower cost options (other than Motorcraft) that are decent? I can't really afford to go first-rate on this repair right now, but I obviously don't want to have to re-do it in a matter of months or a year.

Appreciate all and any feedback!

 

several pages of opinions.

https://www.ford-trucks.com/forums/8...d-on-5-4l.html

 

Thank you so much for the link! I read it in its entirety and it is very helpful!

I didn't see any negatives related to using the Dorman intake as a replacement. In the interest of full disclosure, I have a '04 Expedition with the 2V 5.4, which I understand is essentially the same as the '03 (and prior) F-150s. On another forum I see lots of folks that are critical of the Dorman who say they develop leaks after a year or so and a couple dozen thousand miles. One of the responses on that forum was as follows: "My intake started leaking around 174k miles. I replaced it with the popular Dorman intake. I wasn't super impressed with the quality. But it ran just fine for about 42k miles and then it started leaking. Because the original intake lasted 174k miles and this one lasted 1/4 that, I was skeptical that it was leaking so I removed it without ordering a replacement. I found the Dorman was leaking all along where the aluminum crossover pipe bolts to the plastic."

My driving is extremely easy, but I do park outside in Midwest Winters, so I don't know if that factors into the failure of the plastic (if the non-Motorcraft plastic is inferior?)

I'm looking at some of the products available through Rock Auto: brands like Autotecnica, SKP, and ATP. I can't find any first-hand reviews of any of these. I'd like to buy the intake, waterpump, and a handful of other parts from there, if possible. But I don't want to waste the money and have to do the project again because the aftermarket manifolds are way inferior.

Is it worth the risk? Should I buck up for the extra to buy the Motorcraft? Is Dorman ok? Anyone know about any of these Rock Auto brands?

 

I did not get a Dorman I got another aftermarket one, which one escapes me at the moment.
I noticed that the dorman only had only a few of the brass threaded inserts, in "key" areas where things attach. Where as, the MC one had many more, if not all attachment points.
What I didn't like was where the aftermarket intake just had pilot hole and you were to use supplied screws which are super easy to strip , there by giving marginal holding power, instead of having imbedded brass thread inserts. So I chose one that had more of the brass thread inserts then the Dorman , but still less then MC. Mine has be holding up well....so far. If I had to do it again I'd probably spring for the OEM MC.

I'm sure there are those out there who have had success with dorman.

 

Skip rock auto unless you want to be stuck with no customer service. They fired all their CS and now use a robot server. Lots of miserable customers here. Do a quick search. The dorman manifold is overpriced. The same manifold that dorman sells can be had on Ebay for about 60.00 less. I would reccomend a genuine motorcraft thermostat.
https://www.ebay.com/itm/Intake-Mani....c100935.m2460

 

Good information! I noticed all of the offerings at Rock Auto looked identical with a price range of 30 or 40 dollars, and they all looked identical to the ebay one you linked. My truck's got right at 170k on it and, of course, 15 years old, so I'm a bit hesitant to sink a ton of money into it for Motorcraft parts if i can get 3-4 years and 40-50k miles out of a less expensive aftermarket.

 

I really like your username!

 

I replaced mine 4-1/2 years ago with a DORMAN 615188 from Rock Auto and have had no problems with it. They now offer 4 brands but none of them are Dorman. $130 - $140 plus tax and shipping.

 

Good to hear! I think one or two of their offerings still use that same product number or a recognizable variation of it. I'm leaning towards that at this point. Thanks for your input!

 

If you're replacing the intake, I strongly suggest replacing the temperature sensor on the right head while the intake is out of the way.

 

I have used Dorman on both Mustangs and a 2002 F-150 5.4. There are some minor issues like COP threads and such, but overall they get the job done. I know on one you can't get a normal spark plug socket on one cylinder well without either going thinwall or grinding the socket perimeter down a hair. Don't over torque the bolts on the intake, it's one of those places a good torque wrench saves some headaches.