Lower intake wont seal (OHV)

[fordexploder_96]

Im about to push this thing off a cliff... let me explain

Round one- i bought a fel-pro lower intake gasket set that came with a 2 peace lower intake gasket, its supposedly a new and improved design so installed the kit and used rtv black in the places as directed and to my surprise it leaked....

Round two- i took it apart again re sealed and re torqed everything started it up and it leaked.


Round three- I went back the the parts store and returned the kit and bought a one peace lower intake gasket and this time i installed the intake with rtv to ford specs what do you know it leaked again!

I think your getting the point....

Round four- im starting to suspect the intake is warped so i take the intake to get planed down, the machine shop guy said the intake was slightly out of spec so he planed it down, so i take the intake home reinstalled it this time with rtv going around the water ports and down across the block over to the other water port I did this front and rear of course. started the damn thing up and its still leaking. btw its been leaking from the back of the intake every time.

Im getting pissed I even called a few shops and they told me they didint want to mess with it in case it was i recurring problem they dont want to deal with the warranty work.


Anyone have any ideas to way the intake wont seal?

Im starting to think I have some bigger fish to fry...

:roll:

 

[fordexploder_96]

Bump

 

[fordexploder_96]

bump

.

 

[Runnin'OnEmpty]

FE96, I've been reading your posts and trying to think
of something to cause this.......can't think of anything
except maybe gasket upside down, crack in manifold,
leak coming from upper plenum instead of lower gasket,
etc.....????

Something's not right, after doing this job 4 times,
but I'm not telling you something you don't already
know......

 

[fordexploder_96]

Well I got the intake pulled off i could see a rust line from were the anti freeze was leaking, it looks the the silicone got thin on the rear passenger side water port.

anyone have any tips on how to applying the silicone perfectly?

 

[HahnsB2]

I didn't use the Fel-Pro gasket when I did mine, I don't like how it doesn't seal each end of the valley. I just used a generic brand gasket and it works great. You shouldn't need RTV around the water ports, should only need it at the ends of the valley.

 

[Runnin'OnEmpty]

Well I got the intake pulled off i could see a rust line from were the anti freeze was leaking, it looks the the silicone got thin on the rear passenger side water port.

anyone have any tips on how to applying the silicone perfectly?

Hey FE96, just thought of something.......

Have you been using the same tube of silicone when
installing all of the gaskets? If so, then try another tube.

When silicone gets old, it will NOT cure; it'll stay tacky
for months and will not seal. A tube of silicone is included
in the gasket kits, but there's no telling how old it is......

 

[jd4242]

i had the same problem all i did was to re retorque the bolts 15 min after letting it run(dont let it get up to temp),did you remove the heads also?

 

[fordexploder_96]

hmm, interesting point on the rtv but ive bought a few different tubes from the parts store i guess you never know how old they are though.

no I did not pull the heads

Btw all try re torquing all the intake bolts if it doesint seal.



Thanks for all the help.

 

[fordexploder_96]

well it still leaks. i cant feel or see were its coming from. it never leaked like this before replacing the lower intake gasket but... could it be the frost plugs located behind the flywheel?

 

[jd4242]

how can you tell its leaking?are you just seeing water coming out somewhere and cant tell where?normally they will leak into your oil also if its your lower intake.did you try and retorque the bolts.

 

[fordexploder_96]

its leaking between the transmission and the engine. i also tried re torquing the lower intake bolts. with a brand new gasket and a good application of silicone Im not quite sure what I'm missing

 

[jd4242]

why did you take it off for the first time?have you checked your plugs for water,maybe it a head gasket.i take it your not geting the milkshake looking oil?how bad is the leak?
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[fordexploder_96]

I'd originally taken off the lower intake because coolant was dissipating slowly and cylinder 4 kept fowling plugs and the every morning after letting the car sit it would misfire for 10 to 30 seconds. the oil was always clean, and I did a compression check and I got between 135 and 145 psi across all cylinders. but I'm not ruling out the heads just yet. the leaks a pretty steady stream.

 

[jd4242]

eww sounds like a cracked head!4.0 heads crack like eggs!!have the lower intake magnaflux and if it comes back fine its your head.might know someone with some heads,if hes still got them.belive me ive been in your boat,it took me 4times to get everything right!!
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[Sig Man]

Loosing Coolant

Hi Guys,
I have a '96 XLT,214,0000mi.I have a slight leak (more after its hot,less leak when cold)of coolant,dripping from above the transmission area.Would you say that its probably a head gasket?Having it pressure checked tomorrow.
Thanks,
SigMan

 

[fordexploder_96]

well i just went out with a mehcanics mirror and checked the lower intake for leaks. i did not see any but i was also wasint able to check behind the oil pressure sending unit. I also noticed the leak from were its dripping down below is coming from the passenger side i still cant see anything on top yet to were its coming from.

 

[mikey12450]

new gaskets

ive replaced mine 3 times now and still cant get it to stop leaking. looks like its coming from behind the thermostat housing. whats back there to leak? ive done this type of work before, mow 3 times on this truck, all torqued to ford specs.. im at wits end! what else is there to ckeck. did pressure test to determine it was the lower intake gasket.so whats next? someone please help me!!!!

 

[mikey12450]

what do i replace after lower intake gasket, water pump, thermstat? still leaking above and left of water pump.