Cracked Intake - WITH Aluminum Crossover

[damacman]

Yep, you read that right . . . mine is a 2003 with the "fixed" design intake manifold - you know the fix . . . the one that prevents it from cracking . . . yeah, OK.

I pulled it off tonight and it is cracked on the side with the thermostat housing. Specifically, the aluminum crossover bolts to the composite via six 8mm screws. The composite has a gasket "channel" if you will that an O-ring fits in to provide a seal between the crossover and composite and the composite and cylinder head. The channel is broken and the O-ring was forced out of position, allowing coolant to leak between the outside perimeter of the O-ring and the composite.

So . . . anyone else seen this or am I the lucky one?

 

[lvmustanggt]

 

[damacman]

um-k . . . I guess I'm the only one then huh . . . does anyone else want to see a pic of a cracked mustang manifold? One would think that is fairly common . . .

 

[nesqwick_05]

pic would be required...

 

[DTNODYA]

um-k . . . I guess I'm the only one then huh . . . does anyone else want to see a pic of a cracked mustang manifold? One would think that is fairly common . . .

It's common for a plastic one to crack. I've never heard of an aluminum one cracking so pics would be helpful.

 

[Orange...]

so the plastic part which holds the o rings to the aluminum upper broke? I can say that I have never seen that before, or heard of it either. But I can easily see it happening, because it is still plastic which has coolant running through it...

 

[SRT Handz]

pic is required for this one

 

[old_blue]

mine intake hasnt cracked yet, 112K miles. when should I be expecting this. I know I read a legal post a while back on it. Can I just get it fixed by ford now or is it one of those things where it has to break first??

 

[tank_567]

+10000000000000000000000

 

[5.0's 4 ever]

I have seen it before on a 4.6 crown vic cop car. My dealership has the fleet deal with the local county, if there is any weak link on a car the cops will find it. We have had numerous problems with crown vic cop cars on the "fixed" intake manifolds blowing out the metal pipe at the back of the intake manifold where the heater core hose attaches to. Ford has since changed that 4.6 intake design again to where that it is now all one piece of molded plastic on the back coolant runner, instead of the metal pipe fused into the plastic.

 

[DCjuggalo]

jb weld

 

[Seraphitia102]

and still no pics

 

[lvmustanggt]

he got so much mod and no camera

 

[DropTopPony]

I have heard of a few others with the aluminum crossover that have cracked. Did you contact Ford about it? I'd make them fix it again or have them find you a Bullitt Intake as a replacement and pay the difference.

 

[SRT Handz]

WTF!?!?!...no pics?

 

[njb]

I also have an 03 and my intake did the exact same thing in the exact same place. I just replaced it a few weeks ago.

 

[NX281GT]

Same here. 02 GT, I thought it was the thermostat housing at first. Sucks, exact same spot yours is leaking. Be careful though because I noticed a burnt off coolant trail leading back to the driver's side first spark plug boot- pulled the plug and it was soaked in coolant! I guess I'll try the BBK or TFS intake a little sooner than planned.

 

[Mustang5L5]

So . . . anyone else seen this or am I the lucky one?

I've seen it before. You aren't the first.

 

[old_blue]

still no answer, are all new edge mustangs prone to this weak intake? with 112K on the clock should i be worried?

 

[Killa]

dint those intake come with life time warranty ?