Plastic Intake Manifold Failure - experiences

[Hensley]

For those of you unfortunate enough to have your '96 or newer intake crack, did it give any warning signs? I know I will need to have mine replaced, but would like a few months to save up for it. Just curious if it went when you were running the engine hard, etc., or if it was just random.

[BillyBob TC]

For those of you unfortunate enough to have your '96 or newer intake crack, did it give any warning signs? I know I will need to have mine replaced, but would like a few months to save up for it. Just curious if it went when you were running the engine hard, etc., or if it was just random.
Completely random, ticking bomb. Mine cracked during a routine grocery trip (6 miles r/t). It was on the return home. Im going to say Im a fairly lucky one, mine didnt blow wide open, nor was it far from home. MANY have blown on the highways and such. I think mine blew at the stop light of my street, and only lost about a quart of coolant. Advance had plenty of new Dorman intakes on the shelf too. On the other hand, it was UN lucky as it was February, have no garage, and 2 days from then was a good sized snow storm coming, LOL. Save the $200-250 ish fast as you can if you want to keep her.

[Hensley]

Guess I'll make sure to have my AAA card for the short road trip to Michigan we planned this weekend. Then, start planning on having it replaced.

[Matthew]

You are SO completely living on borrowed time. Don't pass anybody on your trip.

[Hensley]

You are SO completely living on borrowed time. Don't pass anybody on your trip.


I know. I know. But there's no way I can take the old Jeep Cherokee when I've got this beauty sitting in the driveway. I'll drive it like the previous (75 yr old) owner.

[Dusty]

Pretty random, some start slow and some blow fast and hard. Had a friend that drove 4 hours and no problem then took a 10 minute drive to Home Depot and came out to coolant all over the ground.
Only advice that I could give is that if you have to drive it, before you turn it off the engine, turn off the A/C open the hood let it idle for 5 minute to let it try to cool down. Cars get the hottest after the engine is shut off on a hot day.

[micke_932]

If you are unlucky it can be a small crack that fills up one or more cylinders with coolant when you turn of the engine and then you could damage the cylinder heads when you try to start it, so keep an eye on it..

[Hensley]

Pretty random, some start slow and some blow fast and hard. Had a friend that drove 4 hours and no problem then took a 10 minute drive to Home Depot and came out to coolant all over the ground.
Only advice that I could give is that if you have to drive it, before you turn it off the engine, turn off the A/C open the hood let it idle for 5 minute to let it try to cool down. Cars get the hottest after the engine is shut off on a hot day.


Good point Dusty. On our Jeep, with the 4.0L six crammed into the little engine bay, you could cook an egg on the hood after a long drive.

[PROSTOCK]

Mine developed a small leak around the thermostat. I replaced it before it got me. If your somewhat mechanically inclined, you can replace it yourself....no sweat

[Hensley]

I've looked at a couple of writeups, and have thought about it.....but will check out a few independent shops around me and get some prices. I do my own oil changes and minor maintenance, but would really hate to screw this up.

[LincolnCruiser95]

I Had a 2000 Crown Vic LX HPP with the plastic intake manifold. Mine never cracked, but I preemptively replaced it with a high preformance model from Angryducktofuracing ( adtr.net) and had great success, with only a few minor modifications to the under intake coolant hose and alternator bracket.

It took me two days (in december in michigan with a 16 hour long power outage in an unheated garage!) Great Fun!

e-mail them and they will tell you all you need to do the job, If you have any questions, let me know!

Happy Motoring
Charles

[Hensley]

I've heard about the upgraded intake (sometimes called the "PI" one?). You gain a few HP with that, right?

Might as well go with that if I'm going to replace it anyway.

[mark95man]

My 1996 Signature @ 76K miles failed without warning---just a sweet smell and a little smoke as I parked. I stuffed a rag behind the alternator where it cracked, loosen the radiator cap and drove home. This was in 12/2001 and I paid the dealership--$875 but was able to have Lincoln refund me the full cost. FoMoCo knew they had a problem and I stated all the failures I knew of. I told FoMoCo that I planned on listing the failed part on eBay and Autotrader with many photos. This cut through the red tape. VERY IMPORTANT--now would be the time to replace that heater hose running under the intake manifold. You'll be sorry if you don't---trust me on this!

[LithiumCobalt]

My advice is don't pay someone to change it for you. You can get the replacement intake with the revised metal coolant crossover for $200. Spend about $30-40 to get fuel injector o-rings and a new under intake heater pipe and go at it some Saturday when you have some time. It looks complicated, but if you follow the write-up in the Tech section, it's really not that bad at all. Take your time, have a friend help, have a beer every hour or so and by afternoon the job will be done. I have to do this on mine really soon. Good luck!

[Hensley]

I'm giving a little more thought to doing it myself, and save the ~$500 in labor. Any recommendation on a place in particular to pick up the intake? I'll start with RockAuto.

[st0neface]

are you talking about a intake manifold? if so i have one i'll sell for $40 plus shipping

[cason1]

In order to do the PI intake you really need to do the PI heads too. I believe you can do just the intake but you won't get much benefit unless you do them both. The intake tract doesn't line up right between the different versions. Again, I have heard it will work but you will probably lose some power over your stock setup.

As far as where to get one, I'd say look around your local you pull it yard. I got one for a 97 Vic off a wrecked Taxi that had the revised intake installed. That was about 3 years ago and the car is still running great. I think I paid $25 for the intake.

[Dusty]

If you choose new you have 2 choices, Ford OEM which last time I checked there was a Ford delear in Atlanta that had the best price. Other than that there is the Dorman Intake which most everybody else sells. The Dorman comes with built in gaskets, the Ford requires a Ford gasket.
Nothing wrong with going used if it has the aluminum crossover. Many out there have been replaced due to failure or the Ford recall. You will need a new gasket and new o-rings is a good idea. The new intakes don't usually come with the injector o-rings. Going with a PI intake will require more work and parts - a coolant elbow and sealing around the coolant ports with RTV and the OEM has no second temp sensor port. A 96-2000 CV, GM, or Town Car will work. A 96-97 Tbird or Cougar will work as well as a 97-98 Mustang. Just make sure they have the aluminum crossover.
These are pics of a PI version Dorman with the blue & red gaskets and the OEM w/no gasket.
They are not that hard to replace, just take your time. I did not remove my fuel lines, just hung the throttle body from the bottom of the hood with bungees

[LithiumCobalt]

I'd go with the aftermarket firstly because it has the gaskets already integrated into it. Secondly, why trust Ford with something that they already screwed up once. Check Ebay. Prices for the aftermarket Dorman are $200 shipped. Price through auto parts stores runs $250 plus tax.

[96TCE]

I was checking under the hood yesterday just because, and I've also been trying to find the source of my coolant odor. The front edge of the thermostat cover where it meets the intake has some dried up green stuff, and it is also has some below the thermostat housing in the same place, (if the thermostat housing and intake were designed to separate). Now I was looking online at my local parts store and found the Dorman intake Part #615178, http://www.partsamerica.com/ProductDetail.aspx?MfrCode=DOR&MfrPartNumber=615178, listed for $249. Now my question, if my 96 TC had the replacement intake, the front portion where the thermostat goes would be aluminum in color as is the Dorman??

Looks like I'm going to be replacing it sooner than later. I guess I'm one of the lucky ones, where it didn't just blow out hardcore..

[Dusty]

Yes, OEM with the aluminum crossover or Dorman will be aluminum where the thermostat bolts down. This is an OEM PI intake.

[LithiumCobalt]

I was checking under the hood yesterday just because, and I've also been trying to find the source of my coolant odor. The front edge of the thermostat cover where it meets the intake has some dried up green stuff, and it is also has some below the thermostat housing in the same place, (if the thermostat housing and intake were designed to separate). Now I was looking online at my local parts store and found the Dorman intake Part #615178, http://www.partsamerica.com/ProductDetail.aspx?MfrCode=DOR&MfrPartNumber=615178, listed for $249. Now my question, if my 96 TC had the replacement intake, the front portion where the thermostat goes would be aluminum in color as is the Dorman??

Looks like I'm going to be replacing it sooner than later. I guess I'm one of the lucky ones, where it didn't just blow out hardcore..

Now just jinxed yourself hardcore...hope you get it replaced before she blows!

[96TCE]

Now just jinxed yourself hardcore...hope you get it replaced before she blows!

You and me both! I've been babying it, and just taking it back and forth to work (about 15 min).

[Hensley]

I got a Dorman intake on Ebay for $180 shipped. Will be slapped on Wednesday. (plus the under intake hose).

Then I can begin passing people, right?

[Matthew]

Passing people, smoking up your old tires on backroads...anything your heart desires. :D :p