Melted holes in top or intake manifold

[Ruff6548]

I bought my 02 V6 SOHC about 2 years ago, had CEL light for entire time with it running fine, exept once awhile back, had misfires, ran rough, replaced plugs and wires and was back to normal. Finally decided to research CEL, replaced DPFE valve and it didnt come back on, this was 3 weeks ago. Last friday, as soon as I left work, major power loss, would only do 15-20 mph with full throttle at 2000 rpm, 10 miles home. Finally got a day to start checking stuff out under hood, noticed 2 melted holes in the top of the intake manifold. Im assuming this is the reason for it running like it did, but what is the cause? Vacuum leaks? Catalytic converter? Fuel filter? Ive noticed a few questionable hoses so far. Also hear occasional rattling from under vehicle like muffler bracket is loose. Gonna replace intake manifold soon, but want to pinpoint problem first so I dont mess up the new one. Anyone who has a solution will be greatly appreciated. Me, my wife, and two young children depend on this vehicle for everything from getting groceries to doctor appointments. Hope for sound expertise soon. Thank you.

 

[swetrid]

Cats are clogged! It will create so much backpressure that it will melt intake manifold near egr valve.

 

[2000StreetRod]

DPFE hoses?

If the DPFE hoses come loose hot exhaust will exit from them. If you replaced the hoses when you replaced the DPFE sensor and used regular vacuum hose it may have melted. The hose should have a high temperature rating.

 

[Ruff6548]

Update

Thanks for your responses. I pulled off the intake manifold, and it looks like a blow torch was coming out of the pipe that comes off of the EGR that sticks inside the intake manifold. It melted through the top of the manifold. I'm also thinking that it is the catalytic converters. There is 2 of them right? How much will it be to replace them? Can I do it myself? Also, is the EGR valve shot too? Should I replace it as well? Thanks again for the information.

 

[1Aauto]

welcome to the site

 

[Ruff6548]

Thanks 1ATony, hey im having trouble locating an intake manifold for my Explorer, if you read my first post you'll know why I need a new one, also about the EGR and Cats. Any info or parts help is valuable to me, need to get it running right again a.s.a.p. Thanks again.

 

[Cestyrose]

Hole in Upper Intake Manifold

This is the second time in a year that my 2002 Ford Explorer has had this problem and it melted my brand new cat converters as well. Ford settled a class action lawsuit regarding their plastic upper intake manifolds, but I wasn't alerted and didn't have a problem until a year ago. Now Ford won't fix it and I am supposed to pay another $900 for another 1 year/15000 miles?