broken intake manifolds
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Senior User
Joined: Dec 2006
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From: Gray, TN
broken intake manifolds
Im in the process of reinstalling the 300 in my '90 F150 after rebuild. 3 of the tabs are broken off the intake manifold where the thick washers on the intake bolts tighten it to the head. I have the pieces. I pulled another intake off of another engine I have and its got the rearmost tab broken off (the one with the hole in it) I have that piece too. Unfortunately its broken off about 1/16" from the intake port. Ive driven both engines and they both had running problems attributable to vacuum leaks. Does anyone have any suggestions on dealing with this problem? Im thinking of either having one manifold tig welded back together, or trying to find a good used one at a junk yard. I just wanted to find out how common this problem is and if there are any "tricks" other than using a real big washer under the bolt to hold it tight (did not work) Thanks for any help.
Senior User
Joined: Aug 2006
Posts: 113
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From: Texas
I used the "real big washer" trick on mine and it worked, but I had to custom shape the washer to fit flush. It was a hit and miss thing notching out the washer to fit right, but I finally got it and it worked just fine. I actually had 2 broken ears on my manifold, but only had to customize one washer. (the front one)
The best thing is to get another manifold but most of us are on a budget and don't have that option.
The best thing is to get another manifold but most of us are on a budget and don't have that option.
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Senior User
Joined: Dec 2006
Posts: 164
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From: Gray, TN
I tried metal epoxy but one of the tabs immediately broke off like i thought it would. I settled for the real big washer and couldn't get it to work due to the intake warpage. Luckily the man who did my machine work welds aluminum. He gave me a good deal on welding the tab back on and machining the warpage away. I also had him do my exhaust manifolds. He said they were warped pretty bad. I hate to think what a new intake from Ford would cost. I priced a plastic lower intake for a ford windstar 3.8L and it was $900
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