Green '01

Sorry if this has already been discussed but I've been gone a while and searched 13 pages of threads. My intake is leaking coolant onto the #1 coil and I was told the plastic manifold is cracked. I've found a reasonably priced Dorman replacement with upgraded design from Rock Auto and includes gaskets for $168.
Has anyone replaced their own manifold, and what else do I need to do this at home? Don't want to tear into it and find I have to order more stuff and wait until the next weekend to finish it up.
Thanks.

ibd2328

iTrader: (2)

Yes. I have one for sale too

ibd2328

iTrader: (2)

Any model without the aluminum intake or the 03's were very prone to cracking. Overheating can any gasket to bust though. I have a set of gaskets and the 03 entire mainfold if you are interested.

Green '01

Thanks for the offer. What's the difference, if there are any, between manifolds for my '01 5.4 and your '03? How many miles on the '03 you have?

Green '01

Also, can this be done successfully with just replacing the manifold and gaskets? Nothing else needed?

ibd2328

iTrader: (2)

Here is one
If you own a 1996-2001 Ford, Lincoln, or Mercury vehicle, equipped with a 4.6L 2V engine, you may have received a letter last year from a law firm notifying you of a class action law suit. The suit was brought on by individuals who claimed their intake manifold failed, leaving them stuck with the expense of having to replace the faulty piece. In some cases the resulting coolant leakage into the engine caused major engine damage. The lawsuit claimed that Ford was aware the manifolds were prone to cracking and premature failure. We’re not sure why Ford decided to fight the suit, rather than settle out of court or better, simply offer up good customer service and recall or replace the defective manifolds. As was revealed in the court case, Ford certainly knew of the problem…
In 1999, Ford issued three ]Technical Service Bulletins( TSB’s 97M91, 99M01, 01M02) for the cracking problem.
In March 1999 A.R.O’Neill, Director of Vehicle Service and Programs, Ford Customer Service Division, issued an “Owner Notification Program” numbered as 97M91 (1 2) to “All Ford and Lincoln-Mercury Dealers”. This correspondence stated, in relevant part, the following:

While Ford has offered to replace these defective intake manifolds free of charge for cars purchased by police forces and taxi cab companies, they have yet to offer such a “recall” to individual consumers who purchased the same cars. Consequently, consumers must pay for their own repairs if the defective manifolds fail.

ibd2328

iTrader: (2)

http://www.fordmuscle.com/2005/12/fo...ifold-lawsuit/

ibd2328

iTrader: (2)

Starting in 1996, Ford began installing a DuPont Zytel nylon-composite intake manifold onto the 2-valve SOHC engines. Plaintiffs in class action lawsuits alleged that the coolant crossover passage of these intake manifolds may crack, resulting in coolant leakage. A US class-action suit was filed on behalf of owners, resulting in a settlement announced on December 17, 2005.[citation needed]

Starting with the 2002 model year, and implemented halfway through the 2001 lineup, Ford began using a revised DuPont Zytel nylon-composite intake manifold with an aluminum front coolant crossover that corrected the issue. Replacement intakes were also made available for 1996–2001 engines.[50] To be eligible for reimbursement, owners needed to contact a Ford, Lincoln or Mercury dealer within 90 days of December 16, 2005. Further, Ford offered an extended warranty for this part, for seven years from the start date (which means the initial vehicle sale date) without a mileage limitation.

ibd2328

iTrader: (2)

The new dupont style also has no gasket on the lower plenum to replace. The unit is one complete piece with the exception of the aluminum crossover which helps hold the altenator better than the preivous which caused cracking.

Green '01

Thanks for sharing this info - may be of help to other members who may read this thread.
However, in my case, I have the 5.4 and the intake already has the aluminum crossover on the front of the intake - as does the replacement manifold I've been eyeing.