Water leak -Intake Manifold 91' EB 4x4 4.0

[cmayna]

Per a couple mechanics, I have a intake manifold leak. A couple weeks ago, I thought it was the water pump so I replaced it. Shortly afterwards drip, drip, drip.

Both shops are saying that they need to take off about the top half of the engine to do the job which will run around $900 ???? In addition they are saying that many times the long bolt they try to remove shear off thus requiring having the broken studs machined out etc (at $75 each).

Can I assume that this is NOT a home mechanic project ???

 

[bandlow]

Just to pass on my experience, I removed the upper and lower intake manifolds and replaced the gaskets as my first engine related project on my '95 XLT.

I had a shop manual but I think a Chilton's would do fine.

Instead of being hard to remove, the manifold studs were quite easy to get out.

I think $900 is way high to do that job. If you did the water pump, I don't think you'll have any problem.

(I think the most important points are to use a reasonable amount of RTV at the lower gasket corners, position the gasket and manifold correctly [take your time!], and to use the proper torque and sequence for tightening the studs and bolts.)

Let us know how you make out.

 

[cmayna]

Bandlow, How long did it take you to do it ? Was it done because of water leak ?

Thanks

 

[bandlow]

I did it in two approximately four hour sessions. I worked slowly and consulted the book frequently to avoid major mistakes. The first session was for disassembly. That evening I went out to get the new gaskets and had the old ones for comparison. (I got the cheapest I could find since my engine has 112k and I plan a rebuild at 150k. The original Ford gaskets are higher quality than the Felpro but more expensive.)

I had a persistant metallic clicking at all engine speeds which I couldn't isolate to a cylinder. I suspected a valve train problem or lifter but went in ready to stop when I found something which might be causing the noise.

I found that two lower manifold studs had backed out. Additionally the factory had evidently left out one of the two fuel rail gaskets. The lower intake manifold gasket also had a split

Everything has been quiet since and I have noticed that I have to top off the coolant less frequently.

One thing I would do is make notes or photograph every stage of component removal, vacuum lines etc. (I like to tinker and figure out how things go together but I could have saved myself a lot of time during reassembly.

Also much of the time was spent cleaning parts. (Especially upper manifold, fuel rail and injectors.)

If you need more info you can e-mail me at bandlow@compuserve.com

Rich

 

[oahrens]

Yeah...

Ask and you shall receive....

I just spent 6 1/2 hrs today replacing my cracked upper intake manifold gasket . Well since i already was going that far....I replaced/cleaned all hoses, valves, sensors, switches, widgets, do-dads, and oh yeah these things.

I'm too tired/lazy/buzzed to detail a report but I'll do post it tomorrow w/pics if you want. It was on a 91 xlt w/auto trans and a/c.

Here's a post of my symptoms...detailed.
Dead Link Removed

DON"T PAY ......DO IT YOURSELF

 

[cmayna]

Here's my delima, I have 130k on the engine. I guess if I replace the manifold gasket myself then it's probably worth the time spent. How many more miles can I expect before I need a rebuild ?

Obviously this may be a bigger issue if I was to pay someone to do all this work. I would hate to spend the buck doing the manifold only to to a rebuild 30k-40k mile later.

Also what is this thing about manifold bolts being seized ? Is it true that these are natorious in freezing up and breaking ? This was a scare tatic by one of my mechanics.

 

[Grateful11]

Whoa! $900 is way too high. Our Ford dealer said they would do mine for less than $600. I went with an independent and highly recommended local mechanic. He did the complete job parts, labor, new thermostat and all for $285. I don't know how he does it but the guy is good. He stays swamped it took him 2 weeks to get to mine. I just kept adding water until he could get to it. Needless to say I didn't have many tailgaters while it was leaking. Ask around you might be able to find a good local guy.

 

[bandlow]

Two more cents:

I've seen posts that relate engine life up to 200-250k without rebuild. It of course depends on oil change frequency and how it has been treated.

If the manifold gasket is split it should be replaced.

As I recall, the only special tools are a torque wrench and some torx bits.

In my opinion the job is not worth $900. As I mentioned, it was my first engine work and I had excellent results for the cost of the gaskets (less than $100). Just allow plenty of time.

My manifold bolts came out very easily. (In fact two were loose - that was part of the problem.)

The only reservation is that if the same guys who quoted $900 did the troubleshooting, I would verify the problem before diving in. (I'm not sure I would trust them.)

I would do it yourself.

Rich