Tom Werner

I just removed the intake manifold on a 2004 f-150 with a 4.6l engine. Mileage is 219k. I was trying to track down a miss and discovered coolant in the #1 spark plug well.

The gasket was shot, especially around the front coolant passages. I cleaned up the mating surfaces and discovered pitting around the front coolant passages.

I won't be using the truck as a daily driver so resurfacing the heads is not an attractive option. I could take the IM to a shop to shave the mating surfaces down, if I have to. Or, replacing the aluminum IM with a plastic IM may also be an option.

Ideally, I could fill the corroded areas with a gasket sealer or JB Weld and reassemble.

What would work? If filling is an option, what product should I use?

dyeguy1212

iTrader: (1)

How bad are we talking?


I'd just take sand paper to it, increasing the grain count, until it was decent. RTV as opposed to a premade gasket and you're on your way.

Tom Werner

I think it's a little too deep to sand out. I'll see if I can post pictures later.

I'm thinking that I should lightly dremel the corroded areas - kind of like a tooth filling - so that either the epoxy or permatex can bond properly.

While I probably won't drive the truck much, I'd like to do a repair that will last, while still spending as little as possible.

Tom

Tom Werner

Pics of Heads -- Front Water Passages. Intake manifold has similar corrosion, although a little deeper.

knacejr

clean it out the best you can and smear a small amount of blue rtv over it right before putting it back together. use a new gasket too.

redfishtd

That would hone it down flat without valleys . I have done some surfaces like that . Better than sand paper . New ones are cheap .