posted this originally on the expedition side, but should apply to 97-98 f150's w 4.6L as well...

here is the post:

Was going to replace the pcv valve and hose assembly, here's my problem. dealer only has the updated pcv hose assembly, which has a different rubber boot where it hooks into the intake manifold (seems larger - maybe like 5/8" vs existing 3/8", too big for the existing barb..?) . the updated pcv assembly part number is F85Z-6C324-CA. Has anyone run into this? is it possible that the 99' and up intake manifolds have a larger barbed tube for the pcv hose connection than the 97-98 manifolds?

I don't want to go thru the effort of trying to get the existing one off and not have the new one fit. thinking if necessary could use the new tube, but take off the rubber boot and use a short length of <NOBR style="FONT-FAMILY: inherit; COLOR: darkgreen; FONT-SIZE: 100%; FONT-WEIGHT: normal" id=itxt_nobr_2_0>fuel</NOBR> rated hose to go between the new hose and existing barb.

I haven't pulled the old one to verify 100% but visually the new rubber boot part looks larger. can anyone verify / pass on any experience with this?

Big thanks

 

Heads up, the hose assembly that the dealer says is the correct one does not fit as-is, the rubber boot on the intake manifold side is indeed too big. i removed the boot and used 3/8" fuel rated hose to make a union.

 

After several trips to my local Ford dealer, I also got the "updated" PCV-valve/hose assembly part number F85Z-6C324-CA. However, like you experienced, the non-PCV-valve end of the assembly does NOT have the proper hose coupling as my original factory assembly does. This "updated" assembly has a 3/4-inch I.D. rubber coupling, and my original factory assembly has a 3/8-inch I.D. rubber coupling. This 3/8-inch I.D. rubber coupling fits the 3/8-inch O.D. metal hose barb coming out of the rear of the upper intake 90-degree bend. The updated PCV assembly, part number F85Z-6C324-CA simply does not fit. However, my persistence paid-off to locate and identify the CORRECT 3/8-inch I.D. hose to be used with the F85Z-6C324-CA PCV assembly. This hose is about 2-inches in length and slips onto the upper intake's 3/8-inch hose barb and the 3/8-inch hard plastic hose incorporated in the F85Z-6C324-CA assembly.

The proper 3/8-inch I.D. hose part number is:

381402-S019A

The dealer wanted $21 retail for this 2-inch long rubber hose. However, I got the part at the "jobber" price of $11.

Ford's exploded view diagram of this assembly does not readily itemize this small hose! This has been a very frustrating experience to chase-down the correct PCV hose assembly to complete the original factory configuration.

So, get the "updated" PCV assembly part number F85Z-6C324-CA *and* the part number 381402-S019A hose tom piece together the correct PCV assembly for a 1997 F150 with the 4.6L V8 engine.

Note: I could have used a piece of fuel-rated 3/8-inch I.D. fuel line for the 381402-S019A hose at the risk of not passing state of California smog inspection. The 381402-S019A hose does not have any writing on it - a piece of fuel-line does! This is what the state emissions inspectors look for!