Hey everybody,

Just looking for some help on removing an old(possibly original) gasket from my upper intake plenum. The replacement I bought is a paper Felpro, but the one that's on there looks like maybe it's rubber or metal? It certainly looks to be of a different material than the new one.

Some background for anyone that's interested, the plenum came off so I could replace the EGR tube. My truck is a 96', but the engine is a bit older and the tube in there did not have the sample ports needed for me to run lines to the DPFE sensor that is on top of the intake on my truck, not on top of the valve itself. Got an insufficient EGR flow code, and the engine pings pretty bad. I assumed that without the sensor being connected to that tube, the valve was always closed and that was the cause of the pinging.

In any case, the old gasket looked pretty good and I reinstalled the intake without replacing it. Started it up and it stalled out, after a few more tries it stays on but it sounds like a hot rod and there's a strong smell of fuel under the hood. I hear air getting sucked in somewhere, but can't confirm where it's coming from, thinking maybe not replacing the gasket was a mistake. Also, the new EGR tube and Valve did not line up perfectly with the throttle body, the new tube not having a flex joint, so it took a good bit of pulling to get it so I could get the mounting bolts in. I'm also wondering if air could be getting in due to the valve not being perfectly aligned.


I welcome any thoughts on my predicament in addition to suggestions for the best way to get this old gasket off the aluminum intake without destroying it. Truck is a 1996 f150 XLT 4x4 short bed, engine is V8 302. Thanks!

 

As far as removing the old gasket, just take a plastic razor blade to it with some carb, brake cleaner, or lacquer thinner to clean it all up. You can use a metal razor blade, just be careful.

 

Okay that sounds straight forward enough. Just apply the cleaner to the gasket and go at it with the plastic? Should I be concerned about any of the cleaner getting into the intake, should it be cleaned before going back on for that reason? Thanks

 

I'll scrape off as much as I can with the razor blade prior to the cleaner. Any residual gasket material will wipe up fairly easily once the cleaner is applied, then wipe off with a rag. If you don't want any to get into the intake, just spray the cleaner onto a rag then wipe down. If you use a metal razor blade, just be sure to use an angle where it won't gouge the aluminum. Did you clean the mating surface of the upper to lower while it was removed? If not, you may have to remove it, clean both mating surfaces, and install a new gasket.

 

Thanks for the advice, I did indeed clean the mating surfaces on the lower. As an update I used some carb cleaner and actually found my issue at the EGR valve itself. Realigned it to the throttle body and everything seems to be sorted out.

 

A sharp putty knife or razor blade. You just have to be aware if you start gouging the aluminum and STOP