2002 expy 5.4 lower intake manifold
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Cargo Master
Joined: May 2001
Posts: 3,208
Likes: 13
2002 expy 5.4 lower intake manifold
My nephews 2002 expedition with 5.4 engine has been getting p0171 & p0174 errors only when outside air temps are in the 20's or lower. After a lot of testing I have determined that the intake manifold has a leak on the left hand side some where underneath manifold. It appears to be a 2 piece manifold plastic lower aluminum upper. I hear the might be an aluminum lower, but I can't find one listed. It might just be the gaskets between the 2 halfs. But with the work it takes to do this repair I would like to have a new lower and would prefer metal to plastic. Does anyone have a source or part number for the aluminum lower.
Logistics Pro
Joined: Mar 2005
Posts: 4,698
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From: Mexico, Missouri
If metal one was available, it was on the early modular engines, '98-'99. I'm not totally sure. Doubtful. The new intake manifolds have the gaskets built in. I bought the Dorman replacement and has done well. But if I had it to do again, I would by a Motorcraft manifold.
Freshman User
Joined: Nov 2014
Posts: 34
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I had a '96 Jimmy I beat on. I sold it 12 years ago with 171k miles. It's still running around. I think the current owner said he now has close to 250k miles on it and hasn't rebuilt anything. It's close to 20 years old and I'll bet it easily makes it to 24. It wasn't anything special (and a mid size so there wasn't much to pull with it). If I get a KR Expy or a Navigator, it may very well be my last truck (I'm in my late 40s if my math is right so that gives me another 20+ years of driving). Assuming there's nothing inherently wrong (and expensive) with the truck, I can see it being around a very long time. It might start out as a new, luxury truck only driven very carefully to the opera and may end up as a beat up farm truck, but it'll still be there. At least it makes me feel good knowing there's a possibility that an old truck is still running strong after 25 years.
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