4.6L Intake Manifold Question

[Boss Hoss]

Now that I have finally solved my cranking issue, I need to move on to my next repair project.

It starts with this question:

Does the 4.6L stock intake manifold have any coolant passages in it OTHER than where the heater hoses are attached? If so, where are they located?

For the record, I replaced my intake manifold with a re-designed stock replacement a few years back. This question does not concern the typical heater hose leak...

 

[Boss Hoss]

A few years ago, my 1996 GT intake manifold developed the common coolant leak.

I replaced the intake manifold with a new, re-designed aftermarket unit. It had an aluminum coolant crossover. The intake manifold worked fine for quite a while after that.

Now, my intake manifold has developed pretty severe coolant leaks in at least two places--just beneath the thermostat housing, and also near my #8 cylinder.

I recall that my aftermarket intake manifold had built-in O-rings.

I am almost too embarassed to ask this, but here goes:

Was I supposed to use intake manifold gaskets? I thought the O-rings made gaskets unneccesary. Heck, I didn't even think gaskets for this intake existed! And the manifold has worked fine up to now.

I am about to swap the intake manifold yet again...but it got me to thinking. Fel-Pro does make a gasket set for the 4.6L V8. Do I need to buy this gasket set, even though the manifold has built-in O-rings?

I feel like such a dummy, but my car's View attachment 137163 original intake didn't use a gasket set!

I am more than happy to buy the gasket set if I need it...but one thing is for sure: If I DO NOT need the gasket set, I sure do plan on using plenty of Permatex around the coolant passages! I'm tired of these coolant leaks!

 

[The Mach Life]

In many cases as far as parts descriptions go, an "o-ring" and "gasket" are considered the same.

Never had a 2v intake off, but in my 6 years as a tech I've yet to come across an intake with gaskets that are not replaceable.

If you're current one is leaking I'd absolutely buy a new gasket set and any associating o rings. Save yourself the trouble later.

 

[bdcardinal]

The Dorman intake manifold uses o-rings around each port in place of the OEM flat gaskets. FWIW we still get a lot of intakes with aluminum crossovers leaking just like the plastic ones, even on -11 Crown Vics.

 

[Boss Hoss]

bdcardinal:

I wonder if I should go ahead and get another replacement intake manifold, take out the O-rings on it, and use the flat gasket set, with plenty of Permatex. I just don't know if the O-rings by themselves are sealant enough.

 

[wveil3v]

bdcardinal:

I wonder if I should go ahead and get another replacement intake manifold, take out the O-rings on it, and use the flat gasket set, with plenty of Permatex. I just don't know if the O-rings by themselves are sealant enough.

I have the upgraded frpp intake manifold with the aluminum thermostat housing sitting right infront of me with less than 2000 miles on it, it also uses individual gaskets instead of the "doorman intake " with builtin Orings which are prone to leak with movement from heating and cooling. $100.00 shipped.