Trick Flow 51800021 Intake Upper Plenum install

[2002GreyHD150]

hey all... well I thought I would start this here... I had a worn rubber/accordian tube and a crack in the Intake to the TB Elbow around one of the vacuum ports.

So I went looking for options...

Here is what comes in the Box:



YES! including the "custom 2-piece" TB gasket! NOT! so brittle it snapped coming out of the box.

Anyway... Notice the multiple brass fittings included... we will address these individually as we go. <sigh> also the flat metal plate & screw which is the replacement for the cast support for the TB end of the elbow.

I want to note that this specific part # is called out for the Explorer 4.6L up to 2004.

OK so now view these pics:



in this pic the area surrounded by RED needs tapped to 3/8" NPT and will use one of the 3/8npt with 3/8" nipples provided in the box.

for a 2004 Mountaineer, there are a couple of adjustments:

(1) 1/8" NPT plug for the hole nearest the TB
(2) 1/8" 90 degree adapters for the rear port to the fuel pressure regulator & the right most port above the EGR, which is for the Brake Booster
(1) 5/16" to 5/16" barbed union to bypass the water jacket around the lower vacuum port







here you can see the 1/8" NPT to 1/4" barb 90 degree elbow (left) for the brake booster to clear the EGR, the 3/8" NPT to 5/8" straight barb for the PCV, the bottom right 90 degree 1/2" to 1/4" barb for the Fuel pressure control. Also the 1/8" npt plug on the far upper right.

Missing is the area highlighted in red before, 3/8" NPT to 1/4" barb which feeds the multi-prong vacuum fitting.



pics show how the various fittings end up.

tomorrow when I get a chance to drain the coolant, I will show the final install.

Rob

 

[2002GreyHD150]

here is a pic of the coolant feeds to the driver's front PCV tube at the elbow/EGR base



the bottom line comes from just behind the thermostat

the top line wraps around, over the cam cover around to the back of the intake. Definitely coolant related.

Rob

 

[2002GreyHD150]

ok... that's it for today... more edits & adjustments tomorrow after its installed.

Rob

 

[waskly]

you can just pinch off the two hoses, they are to heat up the pcv valve.

and why does that intake have an iac valve cut out. less i'm mistaken thats been long gone on 03 and up explorers.

 

[2002GreyHD150]

the area in red is no longer "IAC out" its just a tapped vacuum location.

If you look here you will see the (4) into 1 adapter & the lil elbow in the old IAC passage, also the 90 degree at top right for brake booster, & the top coolant PCV heater hose.



Rob

 

[2002GreyHD150]

The IAC in the Drive-By-Wire ('04-up) is handled inside the TB itself along with the Throttle Solenoid.

Hence, why the '04-'05s are so sensitive to oily build up in the TB & Elbow.

Rob

 

[2002GreyHD150]

Walsky, just curious... is the PCV THERE on the intake elbow or over on the Cam cover, I honestly don't know.

thanks!

Rob

 

[waskly]

this is where its tricky.

cold states on the upper intake with a bypass or connector in the valve cover.

warm states in the valve cover.

thats all i know behind both designed.


that should just bolt in to the intake tho, i think with a 8mm or torx bolt.

 

[2002GreyHD150]

hmmm... well the Mountaineer was purchased new in St. Louis, Mo.. so I guess I am stuck with calling a dealer with the VIN... lucky me!

Rob

 

[waskly]

hmmm... well the Mountaineer was purchased new in St. Louis, Mo.. so I guess I am stuck with calling a dealer with the VIN... lucky me!

Rob

they wont know......

easy way to tell is look on the drivers side valve cover, is it a pcv valve on it, or just a bypass fitting.

 

[2002GreyHD150]

cool thanks... I will check @ day light.

Rob

 

[2002GreyHD150]

ok looks like Blue-base PCV is in the Passenger cam cover, leading over to the Lower TB elbow. The driver's cam tube runs over to the MAF to TB tube.

Rob

 

[SnookMan]

I did this modification on my 2002 explorer a couple years back....I bought a custom ported and polished plenum from a mustang guy along with a match ported TB. Hers some pics installed

 

[2002GreyHD150]

Snookman... yeah I read about the '02-03 throttle-cable options... but the '04-up are all D-B-W (Drive-By-Wire) so pretty much everything is different.

I WISH I had a 70 or 75mm TB option to throw @ the truck with the Elbow.

but thanks for the pics!

On a side note... my project is on pause for 2 weeks. I got called out of town for work. so I won't wrap this up until early march.

Rob

 

[1Bad04]

I WISH I had a 70 or 75mm TB option to throw @ the truck with the Elbow.

Rob

I believe we do. The BBK 1765. I know it's listed for the V6, but James @ Henson told me about it when I was considering the elbow upgrade. Check with him.

hensonperformance@bham.rr.com