Lower Intake Manifold
 

My lower intake manifold cracked. Its the thermostat housing, right below the hose.

I took it to my mechanic, he said that he would talk to some people about plastic-welding it, but it is not looking so good. And he said that the cheapest he can find a lower intake manifold for is in the upper six hundreds.

Anyone know of a place I can get one for cheaper? I'm kinda pissed that this happened a month after I got this car...

that's ridiculous, you can get a manifold anywhere for less than 200

http://www.americanmuscle.com/intake-manifold.html

check the classifieds there are some for sale by a member here.


mine cracked when I was going around 150 miles an hour on the autobahn

you can change it yourself with simple hand tools. The gasket kit cost me 70 euro but should be cheaper here in the states. The only special tool I needed was a torque wrench.

This is specifically the "lower" Intake Manifold. I'm not sure if that makes a difference.

Let me post a picture of where it is cracked so someone can tell me if the link in the post 2 above this one is what I need to get....



http://i49.tinypic.com/23sc9id.jpg

It's a common problem.

There are PI intakes everywhere, you can get a Dorman replacement brand new for cheap also, if you search around. I bought a couple of them for $100 a piece used a while back, so they're out there and easy to find.

I talked to this guy at a Mustang specialty shop which is local (its called Evolution Performance), and he said I could just get Shorty Headers for just as much. I feel like he's just trying to sell me headers though.

Do you think I would have any luck finding someplace local to get it from (Philadelphia, PA)? Does PepBoys/Autozone sell these types of things?

What do headers have to do with a cracked intake manifold?

And BTW: Shorty headers are a complete waste of money. They do absolutely nothing for you.

Good to know.

And yeah, I thought it sounded weird that the guy was talking about shorty headers

The PI's are not split in 2 pieces like other type of manifolds. This is a very common issue for 99-2000 mustangs. Mine cracked right at the thermostat.

I spent 200 bucks for a new one from Ford. I gave that to a guy who hooked me up with a PI manifold with aluminum crossover. I was in a bind and had to ship my car 2 days after it cracked.

I put a 2003 or 2004 intake on my car and I had to buy a different alternator bracket from the dealership. The new bracket is only 15 bucks.

were here to help and giving you everything you need to know...I have a thread about this back in july time frame.

Another person just bought a dorman intake off of Ebay for like 150 or something like that.

American Muscle is in Malvern PA, just west of King of Prussia. Now they are out of stock on the mani right now but probably not for long.

You should be able to get that manifold any number of places in the philly/NJ area. ( the Ford dealer in Tom's River--downs or towns? would be a good bet)

Additionally, you'll probably need new mani gaskets and a themostat o-ring. might as well get a new thermostat too since it's so cheap.

It's very easy to do the job. Find a new shop--that guy is trying to steal your money.

i think i have the alternator bracket in my garage. FREE to the first guy who asks for it. (could be the old one off my 96 but I think its the newer style--free anyway).

yeah look around you'll find it cheaper than the six hundreds...did that price include install? Even then it's too much...

Also the guy trying to sell you the shorty headers...maybe he thought you said exhaust manifold.

I just got done fixing this same problem. If you go to ebay and type in mustang intake manifold. They have brand new dormans with the aluminum crossover. They sell everything with it also, intake gaskets, thermostat gasket and new thermostat. They are 188.95 with free shipping. Very good deal and works great

Thats what I ordered.

Do you think I could install it myself?

easily... it's about as hard as picking your nose.

it is way easy..an 8mm and 10mm socket is all you need. You may need to get a fuel line disconect kit, like$10

yeah you can do it. take your time, and if you run into any problems stop and post up here for help. one thing, the EGR can be a pita but just keep working with it and it will go ok.

from the pics you already torn down most of the way. looks like you just need to unbolt the mani and then swap the fuel rails over to the new one.

The last one that I did, I left the EGR valve and tube in place, just unbolted it from the upper plenum, and worked around it. It was a lot easier than trying to mess with the EGR tube.

i think i may have done that once also and it is much easier IIRC. unfortunately, by his pics he's already got the upper plenum/TB removed.

now he could take the egr off the plenum, connect it to the tube and then bolt it back on. i guess that would work and make it a little easier.

i didnt even disconnect the fuel rails from the fuel line. I only disconnected the EGR from the plenum and after that removed the intake manifold bolts. It's not complicated at all. I suggest getting a vacuum and a razor to clean up the old gasket.

That picture is actually just one I got online to show where the crack is. I havent removed anything off of my car yet.

I think I might do the installation myself though, I'd rather save the hundred dollars or whatever it would cost me to get it done.

I would not go to a shop that tries to sell you parts that have nothing to do with your problem. I have done it as well and its easy as long as you are good at taking something apart and putting it back together.

How did you know it was cracked?

Probably because it was leaking antifreeze, that's what most of them do.

It leaks like a whore from that spot.

Install is very easy if you had a simple hand tool set. You do need a tourqe wrench which can be had for what $20 at autozone or the like to get the job done. I got mine from Home Depot, I am a fan of Husky Tools, and its been great. Think it was $53 from what I recall.

Sears has their special again on Torque wrenches for $59. The only thing I do not like about torque wrenches is that no one offers them with lifetime warranty. Im sure if you use them correctly no reason they should break but would be nice if they did for such an expensive wrench.