Ford 4.6L V8 Intake Manifold Cracked or Melted Coolant Inlet Fix DIY
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- เผยแพร่เมื่อ 7 พ.ค. 2015
- This is a very common problem to Ford vehicles with the 4.6 liter engine. In fact, there was even a class action lawsuit against Ford because of all the failures--but it's too late to get in on it.
The manifolds have an integrated coolant passage on the front of them which, on the older version, was all plastic and would melt or crack. On the new version it still cracks because, even though the upgraded Ford part has a mostly aluminum runner, it still mates to the head with plastic.
Dorman makes a replacement part 615-175 with a lifetime warranty so if it ever fails you can get another one for free. That's what I decided to install in this video. You can get that here:
www.amazon.com/Dorman-615-175-...
Actually Dorman makes two versions of this manifold. The 615-175 is for 2001 and up vehicles (not sure what the cut off date is) and the 615-178 is for older 1996-2000 models.
The vehicles affected by this failure are (sorry I seem to have lost my list of the various years for each model):
Ford Explorer
Ford Mustang GT
Ford Crown Victoria
Mercury Grand Marquis
Lincoln Town Car
Hope this helps everybody. - ยานยนต์และพาหนะ
Great instructional video. I have a 2000 Grand Marquis that needs a intake replacement and while I have all the tools I lack the experience in some areas. It gets old constantly checking the coolant level and adding to it. You make it look easy.
I believe I read there was a recall on those intake manifolds and I may have even ignored it. Hindsight is 20/20.
This was a great walkthrough , I did this job on my 1998 crown Vic police during the Thanksgiving break (after avoiding the job for a little over a year) , it shocked me how much ease i had doing it thanks to this video. I used a few shortcuts like not disconnecting the fuel line and resting the throttle body to the side after only unbolting it and taking off the two rear houses. I also used a permatex gasket sealer at the top of the thermostat and left it overnight to dry to prevent any potential leaks.
Yes, yes, five years later. Permatex on gaskets that are exposed to coolant is an excellent idea and will extend service life. There is a gasket underneath the crossover on the top side that fails and cracks the housing. Permatex will prevent ingress into gasket channel and stop coolant crystallization.
thank you for the video. I replaced one of these a few years ago and needed to refresh my memory on the procedures involved. watching and listening to your instructions, for me, far exceeded the quality of the instructions of any written or video material i have seen previously.
I am absolutely grateful that you would take the time time to make and share this video with us. you're the man !!
You are our man. Thank you for sharing your work with us. Wow so excellently done and clear. I loved doing mechanical work on my cars until I had an accident where I injured my spine and I am trying to size it up if I would be able to do this. It does involve a lot of stretching on your back. Your video motivates me into doing it. It might take me longer. My car is leaking not a lot, but I know I will run out of time. Thank you again for such beautiful work. Stay safe.
Thank you for videoing your removal of the spacer to stop the leak. I just added a dorman to my crown vic and was worried about what I had done wrong. I had that same leak from the thermostat housing. Awesome video, thanks again!
Now this is a tutorial video! Thank you so much for the tips, clear explanation and slower pace. It helped me so much. Keep up the good work!
Ford should have made the entire intake manifold out of aluminum not just one section.
Yes those plastic/rubber baffles,elbows terminals and fittings are built to melt and spill
Some old school car makers might be turning over in the grave. Others might be jealous they didn't come up with it. .
planned obsolesance.
From what I've read elsewhere, an aluminum intake manifold on these engines suffers from "heat soak", then you have hot air going in, then performance starts to decay.
Facts!!
Edilbrock makes one.
ok. I have been watching you're video faithfully for ~2 months now. Literally every night. I'm finally comfortable enough, and I've ordered my intake. Wish me luck. Thank you for such a great tut.
+Tommy Nolips Nice, good luck
+50sKid
Job done.
The Dorman alternator bracket provided did not fit, i reused my old one.
The job all in all took roughly 8 hours, 2 of those were spent taking everything apart again because i had broken off the thermostat bolt and had to remove the stud from the block.
Against your advice, I used Permatex Ultra Blue Sealant around the coolant passages BECAUSE upon inspection of the block, there was severe pitting around the 2 front passages. I figured to use sealant on all 4 so that it would seat correctly (thats my theory anyways). I had put the sealant on the INTAKE side, but after removal to get the broken bolt out, I didn't like how (in)consistent the bead was, so upon reinstallatiion I put the sealant around the coolant passages on the BLOCK side.
Don't forget to depressurize you're full system BEFORE removing half the engine.... I didn't have pressure in the lines but there was residual fuel in the rail, which happily spilled all over.
The thermostat bolts may be seized in, if it is, pb blast them to get them off. I ended up using my breaker bar to free them. upon reinstall, I greased the bolts and slowly backed them in and out until i was happy i wasn't going to snap it off (again).
For that bastard bolt.... a ratchet with a pivoting head is all thats needed. I didn't bother reinstalling it.
Thk you for such a great tutorial, you literally walked me through every step.
Great Video, I have a 2004 Crown Vic and it failed exactly the same way this video shows. The job took me about 5 hours, and about an hour of that was just cleaning up the leftover gasket, plus I changed the plugs because it was easy with everything off and out of the way. Used the Dorman replacement part as well. I would recommend using the craftsman max axess for the 15mm bolt on the backside of the engine, it made life so much easier.
+Wayne Zimmerman Nice, glad it helped you out.
Dood! Whoever you are...THANK YOU! I just did this on a 2007 Grand Marquis. Your video saved me so much time. I watched it twice and got the whole job including plugs done in 3 1/2 hrs. Thank you sooooooooo much! Ive done a lot of work on cars and this was actually pretty dern easy. I left that bracket off on the left rear. Didnt seem to do anything. One of the bolts is for the intake manifold so I just put a shorter one in. I think it was for earlier models/different models.
glad it helped ya out man!
Hey Tom, I am currently doing the same for my 07 Grand Marqui. What did you place on the heated pcb valve ? my old manifold had nothing there, and the doorman manifold has the threaded hole on the metal piece up on the front. Thank you in advance.
Tom which part number was it ?
One of the better videos on TH-cam about how to correct this issue. My 2003 Grand Marquis had this issue, luckily there is local guy near me that does this job. Cost was a little under $500.00 total. He does this on all the local police cars. LOL I would hate to think how much the Ford garage would charge.
Me and my grandfather tackled this job. Not for the inexperienced. Saved us around $1,000. Thank you sir! Very good video
My is aluminum. It is broke not just a little crack anymore.
I have a pic.
Nice to see some actual trouble shooting as opposed to a perfect install. I'm doing the same on my 2008 CVPI, my gasket failed. Was able to order a new manifold on partsgeek cheaper than other websites.
Great video, thanks. This was 95 percent correct for a 2001 crown Victoria. Saved my bacon. So the presenting problem was a fluid leak near the rear oil pan of the car. When I looked at the top of the engine block there was coolant on top of the block. I was unsure where the leak was, but after watching the video decided the manifold should be replaced. New one on, and the leak is gone. Appreciate the help. 120k on the car when this went out. I don’t see an obvious gasket problem, but i suspect the plastic is warped.
Kraig, how bad was the leak? My 2011 CVPI,140K miles, just developed a very small leak that would drip when not running. Only see it in the front along the oil pan gasket. Top looks dry and don't see any leak by the water pump at all. Thanks Steve
@@stevep756 There's a line to the heater that comes out of the back of the water pump and runs under the manifold, I'd replace that at the same time as the manifold or you'll end up doing it twice like I just did.
It leaks into the valley between the cylinders and drains through the bellhousing, you really can't tell where it's coming from by looking underneath.
That stud with the nut that you were wondering about is for a cable bracket that is bolted to that stud with a 13mm nut. If there was no 13mm nut or bracket it is because somebody failed to replace it. You can remove that stud and the crash bracket as you have shown here, but I decided to remove the windshield wiper shroud which then exposes that hard to reach bolt and makes it easy to reach. The shroud is easy to remove and takes 20 - 30 minutes of easy work. But my approach is to remove things that are in the way instead of fighting with them. Most people would probably work around it like you did. I replaced the manifold on my 2001 F150 and my Daughter's 2000 Mercury Grand Marquis.
I just had the intake manifold done on my 1996 Ford Crown Victoria. Excellent video. New subscriber. Thank you. Blessings to you.
Good video You might just mention in the beginning of your video to drain coolant and disconnect negative battery cable. Also if you use a little silicone spray on the fuel injectors O-rings to make it easier and not roll the O-rings off The use of anti seize on bolt threads and EGR pipe nut will help if you go back latter for repairs.
Great advice,i use anti alot .thread sealant is good also.
man my 04 mustang gt literally started leaking from the bottom of the aluminum crossover thermostat housing, i heard the this is a notorious issue, also the nipple on the rear passenger side of the intake where the heater hose connects to, shattered on me lol. I managed to fix that (long story) but was just searching around seeing how exactly people went about changing the manifold etc. Even though there are slight differences between this 4.6 and mine, the information you gave was very applicable. Yes i actually watched the whole video lol, gonna tackle the job tomorrow morning see what exactly is wrong. Either way great video dude very helpful, Thanks!
Thanks man, glad it helped ya out. Good luck with the job.
How long did this take you overall? I just bought an 05 town car with 179k and discovered some bubbling behind the aluminum part on the passenger side right around where that first injector is so I just went to summit and bought a new intake and heater tube since it will be apart anyhow
Hello good videos. I got questions about swap engine. is about expedition 1998 4.6. what's ford models use the same engine and years?
thanks for excellent video shots and audio and clear explanation and purpose for doing what you did.
question: the dorman at advance auto has $166 without the two brackets. do i need them? if i buy the dorman with the two brackets included its $270. $100 for two brackets that may not
be used is costly for my pocket.
i'm going to attempt to do job on moms 2001 grand marquis 4.6
I have a 2004 Lincoln town car, is the issue fix for 2004 4.6?
Thank you for this video. i just did this project today and saved myself $500. You have a lot of knowledge and experience.
That is awesome to hear!
Thank you Sir so much for this video. You made this very detailed and possible. You have regained my Faith for the Internet, that there is actually useful information on it.👍👏👏👏👏🍻
This is very important detailed job awesome way of demonstrating this job, embarking this job tomorrow!
Mine split on the tube that's on the passenger side rear I used jb weld yellow in color 5min set time an it worked like a charm I also used it once on a bullet hole in my radiator but with fiber patch as a structure an 4yrs later still works great not a problem at all
Is it recommended u drain the radiator fluid before as well?
I am working on my MIL's 2001 Lincoln Town Car. She has a leak at the thermostat and I believe it's because there is no gasket. I am going to get a gasket or just get some Permatex blue RTV. I started working in here and I replaced the plugs and the coils. There was a ton of dirt all around the fuel injectors and such and I did not get it cleaned very well. I had a stripped bolt on one coil so I loosened the Fuel Injector holder thingy. Got everything back together and engine runs fine but I do feel a skip here and there. Could that be because dirt got down in there? Will fuel injector cleaner do the trick?
Did you have a lot of heat inside the car,my my mechanic said it the cats are cloged do you think i should replace the water pump and thermostat?
16:50 important note: the hard bolt is pointed towards the firewall. Not standing up. THAT bolt is a royal pain to remove because a socket wrench won't fit very well and doesn't need to come off yet. the bolt for the bracket is fiddly, but not as hard.
I have the 615-175 Forman intake for a 2007 Ford Crown Victoria police interceptor. My question to the left of the cross over where your #9 bolt to be tightened there are 2 threaded holes. Do you really not need to put 2 screws there?
My 2009 Crown Victoria's 4.6 intake is doing the same thing. The headgasket on the passenger side, in the rear is leaking oil also.
Can leaving that bracket at the back of the intake out cause anything problems?
I kind of figured that. Well let me watch this video once or twice more. I guess... I will go with a Dorman or if you have any other advice before I do so? Thanks
Dorman makes a great kit for this application. Smear a bit of fresh motor oil on those injector rings so they seat easily without rolling... Don't ask me how I know.
For those looking to maintain max performance, get the OEM Ford part. It's more expensive, but the longer runners are good for at least 17 HP in the upper RPM range. Sadly, they're getting harder to find.
thx for the video, how can I quickly tell whether the intake manifold needs replacing (or is about to)? Looking at used Panthers and i don´t want to buy one where I´ll have to replace it soon
+by beyer Look for signs of coolant leakage as I point out in the beginning of the video. Also check for an all plastic manifold without the aluminum cooling channel, that signifies that its the OEM one. But then again, the later models have the upgraded part with the aluminum cooling channel, so, it's tricky.
Great video do you have a video with 4.6 ford explorer?
ATK also makes a replacement manifold that unlike the Dorman is an exact replica of the factory design. Dorman changed the intake runners which kills some top end power. Good video.
Ah, thanks for contributing that!
charlie dee
great video I appreciate all details thank you sir
What was the part number for the dorman manifold?
Do you have experience with the 4.6 2 valve V8 in the 2008 Ford Econoline E250? It seems to only have a cylinder temperature head sensor and not a coolant temperature sensor on that header pipe like yours. My temperature guage is not working so I am wondering if that is why. I was given conflicting responses, some say there should not be a coolant temperature sensor and others say there should. Please help. Thank you.
Do you think it would be ok not to put the sound deadening stuff back
There’s two screws missing right under the crossover, do you not need those?
great video. Thank you for showing us. You are great.
Thanks for the great video. Hoping I never have to do this but I will most likely have to.
If you have a Ford with the plastic manifold and if you put very many miles on it you have a manifold job in your future. They have a very high fail rate.
How did the vehicle sound running before repairs?
What tools do I need for this job?
Nice job While your in, under the intake, in front on driver side cylinder head, replace the cylinder head temp sensor, and wire plug, if need be. Especially, if a mild over heat happened.
I am trying to get the bracket off to the right of the throttle body and already spent over an hour getting the 13 mm "nut" off not a 15mm nut...the stud might be 15mm but there is a plate on top of that stud that according to another video supports yet another plate and a 2nd 13mm nut/bolt. Working on a 2000 Town car...not a crown Vic but what a royal pain
How did you clean your engine bay??
thank you very much, you did a good job explaining and showing I have a ford mustang 2003 gt and its fun to do it you're self save and get my part cheap and the same brand that they trying to sell me for double the price and labor and on and on ....
exactly!
Is anyone aware of a metal intake manifold for the cvpi?
You are awesome!!!!!!! THANK YOU FOR MAKING THIS VIDEO!!!!!!!!!!!
Nice how-to video, I think the intake on my 06 Crown Vic’s 4.6 is leaking in the rear at those coolant passages. My most rear spark plug wells are getting coolant in them. I’m adding about 1/4 gallon of coolant every 300 miles now...
Yes, it's the intake manifold. When coolant is getting into your spark plug wells, it's this manifold.
Neil Ouellette - yep, I replaced my intake shortly after posting.
hello i have question for ya. 02 mercury mountaineer 4.6. intake manifold failed like in this video. i ordered a dorman and i made a misstake and put a set of gaskets under the dorman. would that cause it to leak coolant near the flywheel?
Oh yes, for sure. You need to remove it and only use the dorman gaskets.
i removed my manifold to replace when i cleaned the head i noticed that there is pitting on the head right where the coolant bypass gasket will go. should i use a rtv sealant when i install the new gasket in that section if so what should i use.
Thanks
+jyg101 If you think the pitting is severe enough that the rubber gasket will not squish down inside and make a proper seal, then go ahead and put a light coat of grey RTV on the pitted area.
where are u guys located
I know mine is leaking but it is also burning coolant (both banks). Can coolant also get into the air intake?
I just finished this job on my 97 grand marquis, and your video helped a lot. Thank you.
I have a question about the drill tool you were using. I tried to loosen, and tighten, my bolts with two different drills, and neither had the power like yours did. The drills I had access to were a ryobi 12volt lithium drill, and a Dewalt 20 volt lithium drill. I cannot find any spec on torque for these.
What drill are you using? What spec should I look for? Volts? Torque? RPM?
Excellent, thorough and informative video! Have a customer right now that wants me to do this job. How long did it take you total time?
By the video it took an hour. Lol
@@stevesabo1269 😂
I just had this done on my 07 TC. $920 total. $280 for the manifold ,$600 labor and the rest tax. This was in Calif . I saw this AFTER I told the guy to do it . But at 73 I don't know if my back could have handled bending over that much !
I personally just bought a mustang GT 2002, with 91k and some change on it, come to find out that they had put a new motor in it from jasper. I'm guessing that the engine failed because of this, but there was no documentation from it.
Highest compliments to you with your presentation and knowledge . I felt like I was your neighbor. Subscribe
Great video! Subscribed!
Would it cause a check engine light. The gasket leak
Would a leaking gasket on the 4.6 (I have an explorer) cause you to see anti-freeze dripping from between back on engine block and transmission, dripping onto transmission drain pan bolts (Freeze plug maybe)
Check the nipple on the back of the intake that connects to your heater core maybe a lose hose or the base of the nipple has a crack
Most likely, it's a crack on I take and it usually travels backwards (front of vehicle to rear) and drains down between transmission housing and engine (where they meet) so yes, most likely it's the intake manifold or something under the intake manifold (i.e. heater hose, thermostat or something along those lines) so you probably do have to take the intake off just to find the leak and fix it!
Also, the 4.6 tilts to the rear of the car and has a V valley and and a drain port (of sorts) in the middle hence the leak right where your saying!
I have a 2014 E250 4.6 with a metal intake. Great engine!
About to do this tomorrow to my 2000 mustang gt hopefully I don’t have to buy a new intake manifold just the gaskets but we will see !
How did it go?
Where can I get a intake manifold for my 09 Ford Explorer 4.6 I can’t font it anywhere. Please help
Tascaparts.com has what you need. It is an OEM part, not a knock-off.
Would a cracked intake on a marquis cause low compression test on cylinder 2 p0302 code 81k miles all original parts
If this is going on a car that is just a daily commuter the dorman intake will work just fine. However these units are not a good replacement for the mustang platforms as the intake runners are much smaller and rob hp&tq to the engine. They also have issues with the ports not being big enough to get a socket to change the spark plugs.
Great Video. Thank You
Great video,i was going to say just put the oring gasket on to of thermostat.i did mine two weeks ago.
Is it possible just to remove the bypass without removing the whole manifold I have the same exact area that is leaking and was wondering if I could just remove the
bypass and replace or reseat gasket without removing so much.....Thanks
jyg101 No i'm afraid not. If you have the newer manifold that already has an aluminum coolant bypass channel, it is bolted into the black plastic manifold from the bottom. That's why there is a little layer of black plastic between it and the cylinder head. The bolt is recessed in that little later of plastic. And that's where it cracks. It's almost always the manifold that cracks, btw, but it could be the gasket. No way to know until you get it off. Good luck!
This job is the same for a 98 town car, except for the bastard bolt on the fuel rail crash bracket.
The cowl is shaped different, and isn't as forgiving for space. Regardless don't even bother wrestling the bastard bolt from the side; you will have to take out the wiper assembly and front cowl, because there is a plate with harness attached to the bastard bolt with a nut in front. I managed to use an open ended socket for the first nut, and had to bend the plate a little to be able to slide a wrench in to turn the bastard bolt.
Like I said the video works for a crown vic, but for a town car there is a little more disassembly.
Hopefully this helps someone!
Nice, thanks for the additional info.
Yep Tommy the CV and GM owners don't know how lucky they are been there done that too
Thank you, Tommy. I just wasted the afternoon trying to remove it from my 2002 TC. I'll try your approach. Again, thank for the tip!
Hey man thanks for the video. my Mustang just started doing this in the same spot. Can I pull just the aluminum part that goes across to the passenger side and just replace that gasket? Is there a work around? I am ready to sell this thing I don't want to shell out the money to replace the whole manifold. Mine is leaking where the aluminum part meets the bottom base plastic part on the drivers side. Can't believe what this shitty manifold ford put in my 03 Mustang GT. It only has 107k miles.
Better than the 1a video thanks man
Nice video, well done bro👍👍
Thanks for the video - looking to buy a 99 GT with somewhat low miles (60K). Assuming I'll need to do this soon.
what drive torque wrench should i buy from hf. i am very perplexed by it , always have been confused as to what size drive is used on applications. please recommend.
Just buy the 3/8 one
+50sKid ok thanks a lot
I have 2008 Crown Victoria and I had a PO307 code # 7 engine misfire. I thought it would be a simple fix just change the ignition coil or spark plug and I'm good to go. unfortunately that was not the case, I found coolant around the ignition coil boot. I know the intake manifold is the problem. My question to you what are the chances of a bad gasket and not a cracked intake manifold on 2008 Crown Vic P71 with only 96,000 no including the idling hours?
As far as i know, the chances are low that it's the gasket and not the manifold. The manifold is the weak link.
great video
Where are you located I need my 2004 Grand Marquis intake manifold replaced?
I'm afraid I don't do jobs on the side as I have a full time regular job that isn't car related, so I don't really have time.
Great video, very thorough work. What state are you in?
+Anthony Cliett I'm in California
Would it also be a good idea to change out the knock sensor while your down there?
Not sure but water pump would be a great idea since your halfway to taking the timing cover off
If the knock sensor is working don’t mess
On the same car but a 2009 ford crown virtoria 4.6 after fixing the cooling leak well the car didn't have power
Note: Pull manifold first, unless you just like leaning over a hood. The throttlebody and fuel rails will be much easier to manage once out of the car.
And pony up the extra money for a Ford manifold. I have a lot of experience with this engine and there are performance issues, especially with the doorman manifold and a lot of fit issues with others.
@@TheCottonTop REPLACE WITH THE SAME FAULTY MANIFOLD FROM FORD ?
is it the same steps with the 2001 crown vics
+Andres Diaz Should be, yeah.
The reason why that has a stud coming off of that most difficult bolt you took off is because there is another bracket that goes there...someone may have left it off previously...on mine didn't have to remove alt...I just tilted manifold up to remove and install...
hmm my 2005 4.6 f150 same engine stock aluminum manifold guess they upgraded it on 05 ?
Nice
With the intake gasket leaking will that cause it to overheat
Yes
Will this gasket make coolant leak off the back side of the engine?
Yes skip to 23:58 of this video, you can see the three brightly colored passages at the back of the engine. Those are coolant passages. Another 3 on the front of the engine as well.
So I have the old oring and the new one. One has a beveled look. The other is circular. With both in, the top doesnt sit flush.
thanks 50sKid i have a mercury 4.6 en cancun mx i work for dealer ford used car thanks bro
Good vid,I would stay with a Ford oem intake and separate gaskets as it came from the factory,I have installed a few different brands of intakes not oem and everybody seems to make them, had a few weep coolant after a couple of years,Oem not that much more in cost Regards
hi , can i safely hose the engine compartment down with a garden style hose with the setting on shower ? i don't need to cover any parts or anything?
Yes it's safe
+50sKid so on this vehicle, i dont need to cover the alternator, battery or electrical connectors?
can i use engine degreaser.
DON'T USE A HOSE AS THE SPARK PLUGS ARE IN REASSESSED DEEP HOLES THAT COULD FILL WITH WATER AND KEEP ALTERNATOR DRY
50sKid outstanding ! mine is leaking from the T stat side allowing coolant to enter the # 5 an 6 spark plug wells. causing misfires I don't have the EGR system and will attempt removal with fuel rail connected to manifold. Then determine if I need manifold or gaskets. Also with all the open room I am replacing spark plugs
What did you figure out on your vehicle mine is overheating and the intake gaskets were leaking and I have it completely tore down. But it doesn't miss or anything, so I was wondering if I need to replace the head gasket to
After tearing the car down to confirm the the intake gasket. ( please keep in mind my issue was gasket failure between plastic and the metal below T stat area ) I opted to do the Dorman manifold, plugs, and some coils. I never had overheat just miss fires. Did you do all basic checks with regard to your overheating issue. Head gaskets arent easy with that engine
@@mikes5264 I replaced everything radiator, thermostat,water pump hoses, and I let a Ford specialist technician look at the gasket from the intake and he said it was leaking on both ends.
OK wow I don't like to throw parts unless I am sure there bad. Did you bleed/purge the air from the system. If you suspect head gaskets. See if you could find some with gas analyzer to see if there are any HC levels in the coolant. Also a compression test could be done
@@mikes5264 yeah I even took it to the dealer I had them flush the system out drove down the road 5 minutes starting overheating
Great presentation, Thanks!
Was the vehicle sucking coolant into the combustion chamber?