Do these parts fit your vehicle? Find out now.

Got one to sell?

Got one to sell?

Get it in front of 160+ million buyers.

Ford Explorer Intake Manifold

Ford cars and trucks with a 4.6L engine are prone to developing cracks in the intake manifold. Replacing the intake manifold correctly takes some knowledge and the right parts. Here, you can learn more about the Ford engine problem and how to fix your vehicle.

Which Ford vehicles have an intake manifold problem?

Millions of cars, trucks, and SUVs from several automakers have the Ford 4.6L engine installed. Those installed during the 1996-2001 model years have plastic manifolds that are known to crack along the front or break in the rear. There have also been reports of the rear heater hose connection and front temperature sensor disconnecting. At times, there is a leak before the failure. But in most cases, the damage happens without warning. Once the intake fails, the engine overheats.

What happened to the old Ford 4.6 intake manifold?

After 2002, the engine was redesigned with a better manifold. The features of the newer 4.6L engine manifold include:

  • Stronger materials to provide better support and reduce stress on mounting areas.
  • A completely redesigned mount.
  • A cast aluminum front piece.
How does the Ford 4.6 intake manifold end up cracked?

The rear portion of the alternator was braced to the intake in the original version, causing the belt to pull too heavily on the front of it. Continuous hot-cold cycles and vibration led to intake failure and pressurized coolant leaking into the rear. This level of damage requires a complete replacement of the intake manifold.

How do you replace the intake manifold in an Explorer?

You'll need to replace the manifold, and in some cases, the alternator. Here are the basic steps you'll need to follow in order to properly install your new manifold.

  • Step 1: Completely drain all of the engine coolant.
  • Step 2: Remove all accessories that are bolted to the intake.
  • Step 3: Remove the lifts and bolts from the cylinder head to make the manifold replacement easier.
  • Step 4: Inspect the mounting surfaces for corrosion and the coolant passages for pitting to ensure against ongoing leaks.
  • Step 5: After installing the new intake, tighten the bolts to the proper specifications provided by the aftermarket equipment manufacturer.
What are the torque specs?

The original factory equipment had a lower bolt torque of 18 ft-lb. However, each aftermarket manufacturer supplies their own specs. Failure to check the bolts and fasteners and use the proper specs can cause your new part to crack or get damaged. To minimize damage, tighten the bolts from the center outward, and alternate from side to side. Begin by tightening to 9 ft-lb first, and then finish with the final 18 ft-lb.