Alexei Volkov
Ford truck owners and enthusiasts have been discussing plastic intake manifolds on forums, with some expressing concerns about the potential for cracking. The plastic intake manifold is found in some Ford truck models, including the F150, E-Series, F-Series Super Duty, Econoline, Excursion, and Expedition. These plastic intake manifolds are designed as replacement parts for select Ford vehicles with 5.4L V8 engines. While some appreciate the benefits of plastic, such as reduced weight and improved heat dissipation, others worry about the manifold's durability. Some Ford models with plastic intake manifolds include the 1996-2001 Town Car, Grand Marquis, Crown Vic, and the 2000 Ford Excursion.
| Characteristics | Values |
|---|---|
| Engine | 4.6, 5.4L V8 |
| Models | 1996-2001 Town Car, Grand Marquis, Crown Vic, 1999 F150 4.6 4x4, 2000 Excursion, 2004 GT, 2017-2019 F250/350 6.7L Powerstroke |
| Intake Manifold Composition | Plastic, Plastic/Aluminum Combination, Aluminum |
| Issues | Cracking, Leaking Coolant, Broken Gaskets |
| Solutions | Replacing with Plastic/Aluminum Combination, Repair Kits Available from Dorman |
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What You'll Learn
- The 5.4L V8 engine in Ford trucks has a plastic intake manifold
- Plastic intake manifolds are also found in the 4.6 engine
- The 1996-2001 Town Car, Grand Marquis, and Crown Vic have plastic intakes
- Ford recalled and replaced the plastic intake manifold in some models
- Aftermarket replacement plastic intake manifolds are available for Ford trucks
The 5.4L V8 engine in Ford trucks has a plastic intake manifold
The plastic intake manifold in the 5.4L V8 engine offers several advantages. Firstly, plastic weighs less than other materials, contributing to overall vehicle weight reduction. Secondly, plastic is an excellent material for heat dissipation, allowing for quicker cooling of the engine. Additionally, plastic eliminates the issue of casting flash inside the runners, which was a concern in earlier engine designs.
However, it's important to note that some owners have expressed concerns about the durability of plastic intake manifolds. There have been reports of manifolds cracking or leaking, particularly under full throttle acceleration events. In some cases, this has resulted in coolant leaks and the need for repairs or replacements.
To address these issues, Ford has made improvements to the design. The Dorman 615-188 Plastic Intake Manifold, for example, includes integrated gaskets that sit in the manifold, reducing contact points with the head. This manifold is compatible with select Ford models, including the F-150, F-250 Super Duty, and Expedition, among others.
While the plastic intake manifold in the 5.4L V8 engine offers benefits in terms of weight reduction and heat dissipation, it's essential to be mindful of potential maintenance requirements. Regular inspections and timely replacements can help ensure the optimal performance and longevity of this component in Ford trucks.
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Plastic intake manifolds are also found in the 4.6 engine
The use of plastic intake manifolds in the 4.6 engine has been a topic of discussion among Ford enthusiasts. Some have expressed concerns about the durability of plastic manifolds, noting that they can be prone to cracking and leaking. For example, one owner of a 1996 T-Bird 4.6 reported that their plastic manifold blew out after 6.5 years and around 90,000 miles. Ford acknowledged the issue and provided a replacement manifold made of a plastic/aluminum combination.
To address the concerns with plastic intake manifolds, Ford introduced improved versions with aluminum reinforcements, better seals, and heavier-duty construction. These newer manifolds are designed to withstand the stress of extended use and prevent issues like cracking and leaking. Additionally, the use of silicone-based gaskets in newer manifolds helps eliminate corrosion and vibrations, improving the overall performance and durability of the engine.
For those seeking to replace their plastic intake manifolds in the 4.6 engine, aftermarket options are available. Companies like Dorman offer replacement manifolds that are compatible with select Ford models, providing an affordable and reliable solution. These aftermarket manifolds often include gaskets, making them a convenient choice for vehicle owners and repair professionals.
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The 1996-2001 Town Car, Grand Marquis, and Crown Vic have plastic intakes
The 1996–2001 Lincoln Town Car, Mercury Grand Marquis, and Ford Crown Victoria are known to have plastic intake manifolds. These cars have 4.6L V8 engines, and the plastic intake manifold was also used on the 5.4L engine.
Ford switched to a hybrid plastic/aluminum manifold in 2001/2002 due to a rash of problems, warranty issues, customer dissatisfaction, and litigation. The hybrid manifold has an aluminum coolant crossover, which is known to be more reliable.
Some owners of these vehicles have reported issues with the plastic intake manifold, such as leaks and cracks. It is possible to replace the plastic manifold with an aluminum one, but it is not a direct swap as the runner design is different.
The 1999 F150 4.6 4x4 is another Ford vehicle that was produced with an aluminum intake manifold. However, some sources suggest that the 1996 model year was the end of the line for all-aluminum intakes, with the 1997 Lincoln Town Car, for example, featuring a plastic intake.
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Ford recalled and replaced the plastic intake manifold in some models
Ford Motor Company recalled and replaced the plastic intake manifold in certain models due to the possibility of fatigue cracks forming at the coolant crossover duct. This issue could lead to engine coolant leakage, potentially resulting in engine damage or failure if left unaddressed. The recall affected various Ford vehicles equipped with 4.6L and 5.4L engines, including the Crown Victoria, Lincoln Town Car, and Grand Marquis.
The recall extension, announced on May 25, 2001, by Robert Lane, specifically targeted certain 1996 to 2001 models. These included the Crown Victoria Police Interceptor, Crown Victoria Taxi, Lincoln Town Car Limousine, and Livery Prep Package models. The recall also covered certain 1998 to 2001 Crown Victoria Taxi vehicles and Lincoln Town Car Limousine and Livery vehicles with 4.6L SOHC engines built at specific assembly plants during a defined period.
The plastic intake manifold issue was not limited to Ford trucks but also affected other Ford vehicles, such as the 1996-2001 Town Car, Grand Marquis, and Crown Vic. Some owners of these vehicles reported experiencing problems with the plastic intake manifold, including leaks and blowouts. In response to these issues, Ford replaced the manifold with a plastic-aluminum combination or an all-aluminum design in certain cases.
The plastic intake manifold in Ford vehicles has been a cause for concern among owners, who worry about the potential for cracking. While some have experienced sudden failures during full-throttle acceleration events, others have found temporary solutions, such as soft-pedalling the engine to reduce coolant pressure. Additionally, it is believed that mounting the alternator on the engine block or cylinder head can reduce the risk of cracking in all-composite intakes.
The Dorman 615-188 Plastic Intake Manifold is a replacement option for select Ford models with 5.4L V8 engines. It is designed and manufactured in the USA to match the original equipment in terms of fit, function, and performance. This replacement manifold includes integrated gaskets, reducing contact points with the head compared to the factory unit's carrier gasket design. While some owners opt for this replacement, others choose to switch to an all-aluminum intake manifold to address the issues associated with the plastic version.
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Aftermarket replacement plastic intake manifolds are available for Ford trucks
Ford truck enthusiasts have discussed the plastic intake manifolds in their vehicles, with some expressing concerns about their longevity. Some owners have experienced issues with their plastic intake manifolds cracking or leaking, requiring replacement. In some cases, Ford has provided free repairs or replacements, opting for a plastic-aluminum combination manifold.
It is worth noting that not all Ford truck intakes are made of plastic. Some models, like the 1999 F150 4.6 4x4, feature aluminum intake manifolds. However, it appears that Ford transitioned from aluminum to composite intakes in the mid-1990s, with some trucks from this era featuring plastic manifolds.
When considering an aftermarket replacement, it is important to weigh the benefits and drawbacks. While aftermarket options can offer convenience and cost savings, there may be concerns about their longevity and reliability when compared to OEM (Original Equipment Manufacturer) parts. Some truck owners have shared mixed experiences with aftermarket intake manifolds, with some praising their performance while others encountered issues requiring additional repairs.
Ultimately, the decision to opt for an aftermarket replacement plastic intake manifold depends on individual needs and preferences. While these aftermarket options provide a viable alternative to OEM parts, it is essential to carefully research and consider the experiences of other Ford truck owners to make an informed choice.
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Frequently asked questions
Ford truck motors known to have plastic intakes include the 4.6 engine in light trucks, the 5.4L V8 engine, and the 5.4L Triton engine.
Ford trucks from the mid-1990s to the early 2000s are known to have plastic intakes. This includes the 1996-2001 Town Car, Grand Marquis, and Crown Vic, as well as the 1999 F150 4.6 4x4 and the 2000 Ford Excursion.
Plastic intakes were commonly used on Ford trucks during the late 1990s and early 2000s. However, some owners have expressed concerns about the durability of plastic intakes, and some newer models may have aluminum or composite intakes.
Plastic intakes have some advantages, such as being lighter and dissipating heat more quickly. However, they have also been known to crack or leak, particularly if the coolant crossover is made of plastic. Ford has recalled some models with plastic intakes and replaced the manifold with a plastic/aluminum combination.
Yes, it is possible to replace a plastic intake with an aluminum one. However, it may require some modifications and careful selection of parts to ensure compatibility. It is recommended to consult a mechanic or a Ford specialist for advice before making any changes.
