How to Replace Upper Intake Manifold 97-06 V8 4.6L Ford F-150

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In the video, 1A Auto shows how to remove, replace and install an old, rusted, corroded or leaking upper intake manifold. The video is applicable to the 97, 98, 99, 00, 01, 02, 03, 04, 05, 06 Ford F150 with the 4.6L V8 engine
🔧 List of tools used:
• Flat Blade Screwdriver 1aau.to/oBx/1AXAA00013
• Pry Bar 1aau.to/ocp/1AXAA00020
• 19mm Wrench 1aau.to/off/1AXAA00010
• 10mm Socket 1aau.to/os7/1AXAA00017
• 11mm Socket 1aau.to/owu/1AXAA00015
• 8mm Socket 1aau.to/os7/1AXAA00017
• Adjustable Wrench
• Needle nose pliers 1aau.to/odM/1AXAA00051
• Needle nose pliers 1aau.to/odM/1AXAA00052
• 1/2 Inch Ratchet 1aau.to/ogn/1AXAA00043
• Ratchet 1aau.to/oBV/1AXAA00016
• Socket Extensions 1aau.to/owu/1AXAA00015
• Torque Wrench 1aau.to/oik/1AXAA00044
• Anti-Freeze
• Anti-Seize Grease
• Engine Oil
• Gloves 1aau.to/oa6/1AXSS00048
• Painter's Tape
• Paper Towels 1aau.to/ocE/1AXSS00035
• Rubber Vacuum Hose
• Safety Glasses 1aau.to/oD/1AXAA00343
• Drain Pan 1aau.to/occ/1AXAA00320
• Pick 1aau.to/ocH/1AXAA00037
• Razor Blade / Gasket Scraper 1aau.to/oab/1AXAA00280
• Rubber Mallet 1aau.to/oJ/1AXAA00413
For More Info visit us at 1aau.to/h/6e/
⚠ DISCLAIMER:
While 1A Auto strives to make the information provided in this video as accurate as possible, it makes no claims, promises, or guarantees about the accuracy, completeness or applicability of the content. No information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. All do-it-yourself projects entail some risk. It is the sole responsibility of the viewer to assume this risk. 1A Auto is not responsible or liable for any loss damage (including, but not limited to, actual, consequential, or punitive), liability, claim, or any other injury or cause related to or resulting from any information posted in this video.

[@1AAuto]

√ *Watch the Video* √ *Buy The Part at 1A Auto* 1aau.to/m/Visit-1AAuto √ *Do it Yourself* √ *Save Money*

[@powellwlord]

I just change my intake manifold. Word of advise on the older model f150s people if you're gonna change the water pump and the thermostat you're likely gonna need the manifold. The manifold was ok until I change those parts. After doing so the truck gain a lot of power and the air pressure also build up. So if put a strain on the intake start busting hoses an all. Another quick succession if you are leaking antifreeze check your heater hose at the back of the intake. The original hose has this hard type plastic that runs through the rubber hose its a culprit to crack. When it leaks you don't even notice it because it's at the back of the intake manifold and it leaks down and end up at around the middle of the truck on the passenger side.

[@1AAuto]

+Andrew Powell Thanks for the feedback!

[@crazymc3909]

@@1AAuto question is the 4.6 process the same as 5.4?

[@JoBar12006]

BTW when you're down to replacing the gaskets, many of these if not all the 4.6's have a coolant house that runs along the top of the motor under the intake, visible after you pull the intake, REPLACE IT WHILE YOU'RE THERE. 1Aauto carries it or other places, it's well worth replacing it now as opposed to later when it breaks and having to repeat this entire process for a $20 hose.

[@wethepeople536]

What else should you replace because you are there?

[@Acordionista509]

What's the hose called?

[@sgt.hollowpoint6968]

I tackled this exact project about 5 years ago. It's not hard, but does require lots of time, and patience. Proper tools also help. It's doable, but watching this video prior to taking on the task, is very beneficial.

[@randycook3389]

Thank you for the instruction. I just did an intake gasket replacement on a 2001 F150 based on this video. Some items were a little different, but nothing was hard to figure out. Also, my truck doesn't have the benefit of a lift kit, so without the extra overhead clearance I just removed and replaced the manifold with the lower plenum intact. It was a tight squeeze, but it worked and saved a lot of difficulty.

[@schrodingerscat4737]

Amazing video! Absolutely love the step by step process. I'm not a big Ford fan and avoid it like the plague. But I have a client tomorrow so this really helps dust off the old cobwebs. I noticed however, at the 18:30 mark. You removed the intake bolts starting from passenger side ending on the driver side. My mentor always grilled me about removing and replacing in a center-out, star pattern. It balances the stress on the mating surfaces. "A little here, a little there, or you'll end up paying for the whole divorce." ~J. Jones

[@JoBar12006]

Removing and installing hard to reach bolts- use a stick magnet. Before beginning relating to dirt around the intake holes- blow the top off thoroughly before beginning. If you don't have ready access to an air compressor, stop by a mechanic shop, they'll usually oblige you to simply blow it off. If that's not an option, spray WD-40 around the intake BEFORE beginning, next best thing to keeping loose dirt from freely falling into unwanted spaces. But still another great video from 1Aauto!! Thanks for the helpers!

[@davidbaker9583]

This is a great video and very helpful for me when I changes the gasket on my 98 Ford F150. Doing this job fixed numerous problems with my engine to include oil in the coolant, coolant leaking into the intake port, and coolant in my oil. The truck runs better than at any time since I have owned it during the past 12 years. Adding a couple of extra recommendations, The EGR tube was locked tight so I used a 1 inch copper pipe for more leverage and prying on the nut; I hit it with a hammer and it broke loose. I also bought a deep well 8 mm socket with a 3 inch extension to get the bolts in the back. The space in the back with no lift was very hard to get at but this worked for me. Also, I dropped tools and hardware taking it apart that went under the manifold because of the tight space. When I put it back together, I stuffed rags around the manifold so when I dropped a bolt or tool, they didn't go under the manifold where I couldn't recover them. With the rags in place I could see them and reached them with a magnetic parts retriever. I also cleaned the injector ports that were full of carbon. With the manifold removed, changing plugs, wires, and injectors is a very easy job and not real expensive if you have any doubts about the possibility that you will have to change them in the future. After I cleaned up the old aluminum upper manifold it was in great shape so I reused it. The lower manifold did not look all that great so I replaced it. Again, for not much money. I also used a Fel pro, more expensive gasket, that was very strong and durable and I didn't have to worry about screwing up the gasket when I put it back together working in the tight space. Wish I had done this job 10 years ago when I was younger and my health was a lot better.

[@1AAuto]

+David Baker Thanks a lot for the great feedback and the tips! We'll pass this info along to our production team to possibly include some of this in any future repairs/videos we make for this vehicle.

[@israelramos5356]

Man, I just changed out the manifold on my 2001 f150. This video and my brother were a huge help. Thanks!

[@rafaeljaime4013]

I love 1A auto repair videos, main reason I buy my parts from them so they have a reason to keep making them

[@1AAuto]

+Rafael Jaime Thank you very much! We appreciate your business and feedback.

[@joeysanchez5926]

Me too and they have an actual phone number to call.

[@TroyStevensStelzerPaintingInc]

Out of countless vids regarding upper intake replacement, yours is by far the best. Extremely clear & concise, wonderfully filmed, and without a ton of needless fluff. About the only critique I'd have would be questioning why put on the old injector o-rings when new ones cost a few bucks at most? Reusing injector o-rings creates a very real likelihood of future leaks, at least once you've removed them from the injector bodies. Still though, awesome job. Thanks for your contributions.

[@1AAuto]

+Troy Stevens Thank you! We love empowering our customers and showing how to perform DIY auto repairs with our high-quality auto parts. 1aau.to/m/Shop-1AAuto-c

[@doubleHLabs]

This video works! I bought the parts and coolant for about $500. Would have been cheaper, but I needed fuel injectors. Did all the work myself following this video. The only issue I had with the video was at about 40 mins in you skip attaching the spark plug connectors, which was very easy to figure out.

[@1AAuto]

+Dave Thanks for watching! We love empowering our customers and showing how to perform DIY auto repairs with our high-quality auto parts. 1AAuto.com

[@travislynn21]

Thank you for the walk through. A1 auto is the best repair information I've found! Plus the best prices on parts. You guys are awesome.

[@1AAuto]

+travistreetrimmtrucking Thank you for checking us out. It is greatly appreciated. Have a great day! 1aauto.com

[@TheAfrozilla92]

Leaving a like because this video helped someone like me who is not a mechanic pull, and replace his intake manifold. Great step by step. Thank you!

[@Amertrade97421a]

One can disassemble both the upper and lower intake manifolds outside the engine compartment. A lot easier than doing it in position. The reverse is also true!

[@dash-ng4er]

I love you guys y'all have helped me so much with my 4.6 with doing new head gaskets and I have used so many of your videos to figure out where stuff goes or how to take the parts off

[@bbay1977]

Wasnt the job I need done but I love to watch you videos so I educate myself. Thanks for the upload.

[@1AAuto]

+James B Thank you for your feedback! We are happy we could help.

[@realcombatsportstalk1030]

Love these videos!!!!!!!! Very detailed steps, makes it alot easier. Along with these videos, I usually press record on my phones camera so I never forget where what goes where. Thx 1A Auto!!!!

[@aarongibson3947]

Very well done. Clear and was able to get my truck back up and running.

[@pacotarasco8469]

Thanks so much for the step by step that I’m just doing a replacement my truck 97 F-150 thanks for you video

[@samrap7928]

Paco Tarasco was it different for the 97?

[@markzanetti6228]

wow... excellent video. maybe the best i've ever seen for a mechanical instruction video.

[@sirronbailey3109]

Thank!! He had definitely save me a lot of headache thank you so much I cannot begin to thank you.

[@michaelmartinez1345]

Awesome video! This guy is good!!! The only mistake that I noticed is he did not put a rag into the throttle body intake port of the manifold-during disassembly, or re-assembly... Other than that, it was stellar, what he did here!

[@1AAuto]

+Michael Martinez Thanks for the feedback!

[@romanescalera7752]

Los mejores videos, muy profesional. ¡Gracias!

[@amatexan6536]

Nice job.Informative,and in great detail.Thanks a whole bunch! Nice background music too.Not to loud or crazy.

[@1AAuto]

+AmaTexan65 Thank you for the positive feedback. We really appreciate it! If you have a minute, drop us a review on our Facebook page to let other people know about your experience with us. Here's a link: facebook.com/1AAuto/reviews/

[@lymelyte225]

Thank you for this video. It saved me some money and gave me an excuse to buy new tools!

[@1AAuto]

Thanks for checking us out. 1aauto.com +lymelyte225

[@whereman1199]

Great video, but you failed to show the gaskets on the manifold and throttle body. And you failed to mentioning the presserazation of the fuel system. I think these points are important to mention. Lastly will the vehicle need a tune becuase the system was torn appart?

[@mikencrew8885]

Thank you!!! This will help out tremendously when I get ready to do this

[@brentsmith6239]

Why not remove the upper and lower at the same time

[@infantryfreak]

Why did you replace the aluminum intake with the plastic one? I thought the plastic was more susceptible to cracking?

[@MikeRuskinMcSkin]

also if your reusing aluminum intake do not use the plastic/rubber gaskets, heat will crack them in a hurry...only use the metal/rubber style...

[@celleduffel1533]

sat here grinning and shaking my head..ya'll reminded me of my ex and his fixing old cars and trucks..Robert, did not know Aaron had his own channel..can you put it out?

[@XynGG]

Major life saver! Will be buying parts from you guys. Thanks again

[@1AAuto]

+CrashLabs Thanks for checking us out! 1AAuto.com

[@rural_old_dude]

Tyvm, planning on doing it tomorrow. 1 question, my truck has no body lift, but would it help to Jack up both sides of the front of the truck to raise the body up off of the wheels? Would that give me more room? Thanks

[@marylamb6063]

Excellent video. Thank you. It was an easy job.

[@DJTinyTim13]

If I’m replacing the aluminum manifold, not going with the plastic, are the torque specs the same?

[@rishonosuna7509]

Great video really helpful

[@usaforevergodblessamerica5793]

Great job guys

[@medixar]

This was incredibly helpful. Took 8 hours but also changed plugs/boots/coils and cleaned injectors. Thanks!

[@theeclipseshow2432]

can i assembly the other part (the black plastic botton forgot the name) outside with the top side and bringit in to the engine as a whole assembly on just one part???

[@TheOfficialSoulfire]

Thank you followed your instructions step by step

[@1AAuto]

+AC Thanks for checking us out! 1AAuto.com

[@classicstangbrn8964]

Thanks your videos are always helpful. Just wondering if you can attach that lower plenum to the upper and install all together, seems like it would be alot easier at least for me? Mine is a 2000 Expedition 4.6 and it's really tight, also mind has a vaccum leak instead of coolant.

[@1AAuto]

+Classic Stang brn We don't believe that you can but thank you for checking us out!

[@ginagonzales7298]

What are the two temp sensors? Ive been looking for the correct ones. Do you have a link for them for yalls website?

[@jonscott365]

So for the f150 lower intake f65e is that the longer dowel or short ones

[@patrickcordery1635]

What is the torque specs for the cross over tube on a 4.6 v8 2002 ford explorer thanks

[@ericdehart5626]

I’m currently doing mine though the previous owner put gasket sealer on the lower intake gaskets not sure if that’s needed. Anyways is there a video on head gaskets for the 4.6l?

[@carlosarce5013]

Thank you Sir.

[@WTFIsThisGuyDoing233]

Best one on youtube

[@caseywolf3812]

Would this intake Manifold would work for the 97 f150 5.3?

[@solluna2155]

Good tutorial, thank you 👌👍

[@1AAuto]

Thanks for checking us out. Shop here for high quality auto parts: 1aau.to/m/Shop-1AAuto-c +SOL LUNA

[@ednelo85]

I need to do this to my truck, 2003 f150 4.6 I have coolant leaking into the spark plug well

[@thepandamechanic5621]

I just got a deal on 2003 f150 5.4 for 2k has this problem. i bought 469$ in parts (coils plugs and intake) doing it tonight. very common issue. nothing to worry about =D it has 230k miles

[@robertthewolfman]

Any 5.4l v8 intake manifolds coming in soon I hope ?

[@joeysanchez5926]

I'm gonna be doing head gaskets so will need to order everything from you guys. I prefer y'all because of the videos and customer service phone number.

[@1AAuto]

+Joey Sanchez Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c

[@juanjosehernandez2608]

Wonderful video . Thank you

[@lorenasoria5957]

GRACIAS TRABAJO PERFECTO

[@1AAuto]

+LORENA SORIA Thank you for your positive feedback! We are happy we could help.

[@nobodyknows8725]

Can you just replace the gaskets or do you have to replace the manifold at the same time?

[@kennyortega7608]

Hi Ron about how much does is cost to do this job? I have a 2000 4.6 get Mustang and I believe I have the same issue with coolant underneath the thermostat housing. Seems to be intermittent thought for now.

[@LuisPerez-hf6rv]

I have an 03 4.6 Expedition, and the lower manifold part number starts with the 1L1E, which insert bag do I use?

[@scottbauries2302]

Great video for a novice like me with a recent purchase that needs work. One question--why is your air filter housing partially cut away, exposing the filter to view? Is that a trick to bring more air to the engine?

[@rob5598]

I did that simple "mod" to my 03 expedition with the same engine. You do notice a difference in throttle response, esp if you have an open exhaust system. Ive since then bought a cold air system. that was a "quick fix" back when i was younger mechanic. 😁

[@michaellarcom]

Do you have any videos of the upper intake manifold removal for 1997 Ford Explorer? There's a line on the driver's side front of the upper intake that has a clip you pull out and I like to know what it goes to. I hear a leak from between the upper intake and lower and when I pull up on that line it gets quite and my trans shifts late.

[@1AAuto]

+Michael A Larcom Sr We currently do not have an auto repair video that covers this particular repair. We will keep this request in mind in the event that we need to make this repair in the future. 1aauto.com

[@robertbarnes2564]

instead of taking the bolts that attach the upper and lower intake together can it be removed in one piece? And then taken apart outside the truck? seems like it would be easier to do it on the work bench. Or is there not enough room to remove both while they are bolted together? Great video by the way I plan on doing this this weekend!

[@1AAuto]

+Robert Barnes It's not something that we have tried. You may be able to service it this way.

[@epifaniobarrera2330]

very nice and helpful

[@Viperboy16]

great video, but I have a question, can I use this guide to change it on a 1998 f150 4.2 ?

[@1AAuto]

+Viperboy16 We're always cycling through common cars. We'll add this repair to our list! 1aau.to/m/Shop-1AAuto-c

[@cards06champs]

I'm about to do this job on my 03 f150 4.6 4x4.

[@chadspradling7627]

Hmm mine doesnt have those 2 temp sensors like that in front of the intake, wonder why? I just started taking mine apart to do a knock sensor. It's a 1999 ford f150 4.6l W

[@BasicallyBennie]

Thank you so much!! I needed this

[@1AAuto]

+Basically Bennie Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c

[@2Spookeh4Me]

Can you please tell me the part number for the O ring that goes on the "tuning valve" or "runner valve" on the plastic "box" under the intake manifold? I can't find it anywhere. It's outer diameter is 2.60 inches. Thank!

[@EestiTammela]

As I continue to watch this video, I cannot help myself but get even more excited & nervous as I’m about to take on this “upgrade” myself. 😁🤭

[@1AAuto]

+Adam Tammela Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c

[@pyrotunz]

Excellent video!

[@cards06champs]

Best video by far! Thanks!!

[@edwardvasquez218]

Intake looks clean. Mine was super dirty.

[@PGH412]

Have a coolant leak behind the engine, I'm assuming its the intake manifold or the hose that runs behind it, either way both have to come out. I can't imaging it going this smoothly.

[@RGVNuevoLeon]

You can also you a magnet to the socket extension and help better

[@emilio3503]

Need help I have a Ford f150 5.4 1999 what is the dormin part number for the plastic upper intake manifold.

[@javiercastro9326]

great video! congratulations!!!!!.

[@1AAuto]

+Javier Castro Thanks for watching. If any of our viewers needs to make this repair, we carry the auto repair part shown in this video on our website. Here is a link to them www.1aauto.com/ford-intake-manifold-with-integrated-gaskets/i/1aeim00032?KZbin&CTA+Comment&FLIjfcXeAa4

[@isaackshirley4695]

Hi does the throttle body have to come off

[@Michael-hv3ts]

Great video. Thx! Just got my 2003 F150 w/ 5.4 back with the bad news of the intake manifold having issues and therefore won't pass emissions. Can't justify spending the money they want for this old 'APF' truck, so I'll do it myself. Just curious, why did you not keep the original manifold if it was still in good condition and just replace the gaskets? Maybe you mentioned why and I missed it. I get that they're not that expensive but just wondering. THX

[@ashemoski]

Agreed. There's no reason to replace the metal intake with a plastic one. In fact, I'm getting ready to install a metal one from a '99 F150 on my 2003 because the plastic cracked under the coolant crossover connection (a typical failure on the plastic intakes).

[@tylerzorn6560]

Whats the name of the vacuum boot that connects on the back the intake on the passenger side? I can’t seem to find anything on it, be very appreciated if someone could point me in the right direction bc i need one

[@simono.9047]

Professional job great work,Sir

[@Acordionista509]

Did you have to de pressurize the fuel rail?

[@MAGWolf]

Plastic manifold in no way was upgraded version. They cracked and were junk. Other then a small amount of corrosion that could be cleaned I would have put the aluminum one back on.

[@rob5598]

I switched back to aluminum for that exact reason. 👍

[@Acordionista509]

Can I replace just the crossover pipe?

[@riverdeluca6312]

Can I buy the throttle body elbow from y’all I can’t find a auto parts store that sells it ?

[@SasukeGarage55]

is the same step for the 5.4 v8????

[@caseysmith5168]

My 02 expedition starts right up but slowly bogs and dies parked and while driving, but only when it's cold outside. Any knowledge on that?

[@1AAuto]

+Casey Smith Unfortunately we cannot really accurately diagnose that. We would advise you take it to a trustworthy mechanic in your area that can look at it in person

[@richardcolvard3111]

How much torque on intakeanifold

[@hubert-williams3379]

ok, so the spark plugs remain in the spark plug wells and do not come out with the manifold?

[@jonboy5669]

Will this tutorial also work on a 5.4l engine? I have a 1997 f250 with the 5.4 triton engine and I think I need to replace the intake manifold.

[@1AAuto]

+Jon boy It may be a different procedure on that particular year, make and model truck. Thank you for asking. 1aauto.com

[@charleswilson4598]

I did a 5.4L v8 a few years ago and it is a different manifold, but thee are a lot of videos on youtube for that engine.

[@douglasking6714]

What about the lowers they come with the gaskets but can't find a video of the lowers

[@babblingidiot7903]

Are these plastic intake manifold good? I have the alum one but it cracked. Not sure to source out a used alum or buy these cheap looking plastic manifold.

[@YourFavDieselTech]

That egr tube nut is 1 1/4 if you don’t have a big enough adjustable.

[@wyattsdad8561]

I was wondering why not take the lower manifold out with the upper and do the assembly on a bench?

[@Acordionista509]

Is this the same for a 5.4?

[@kennethdurbin3385]

Anyone have to swap out their upper intake manifold on a 2013 F150 5.0 yet? Just ordered one as I'm sure mines been leaking for several months.

[@chasingblessings1904]

How do you remember where all the hoses and wiring goes?

[@HaloDaycare]

Since the plastic manifolds are prone to failure, can you find ford aluminum intake manifolds?

[@1AAuto]

+HaloDaycare Daily BO4 Vids Thanks for watching! We do not sell a fully aluminum intake, but we do sell one that is an improvement on the factory design. Here is a link to it: www.1aauto.com/*/i/1AEIM00032?AKZbin&Adescription&Avideodesc&FLIjfcXeAa4

[@TheRoguelement]

Dear 1Aauto...You Never mentioned word one about intake manifold gaskets in any manner other than when you removed them...in fact you sat the intake down without ever saying a word about gaskets...

[@WesThomas-xn5mf]

I have a 97 f250 2wd 5.4 propane truck factory 100,000 miles great shape in and out ,one of things my uncle left me ,I wanna convert it to gas ,before he passed he was in the process of making it natural gas,so project unfinished sadly,it still has three large tanks one under belly two in bed I’m in the process of taking everything propane off ,next step would be greatly appreciated,can I use same i tank? Put gas tank on run lines and go? Lol

[@TheWaverider09]

What is the plastic rectangular box under the intake manifold ? Great video , well done !!!!

[@WCGwkf]

I think that's the plenum. Air goes from throttle, down inside that box and back up into each intake port, unless I'm mistaken.

[@PFLEONARDI0906]

@@WCGwkf YEP

[@clc6377]

How to did you do this without changing the Intake Manifold Runner Control Module? Maybe I missed that part? Did it come already Installed on the Intake? You didn't show or talk much about the back side?

[@CryptoJunkie]

Is it safe to clean the intake elbow after removing the throttle body off of it? Or do I need to remove the elbow and clean it when it's disconnected from the manifold? I want to clean the EGR ports and I can't remove just the EGR valve because the EGR tube nut is completely rusted and stuck and nothing will take it off. Let me know.. Thanks! You guys rock!!

[@1AAuto]

+Yo Daddy Thanks for checking us out! We would highly recommend trying to get that nut off in order to properly clean this. While it is possible, we would not recommend it due to the pressurized nature of the cleaner. 1AAuto.com

[@trumpisyourpresident7810]

Will work on the 5.4 as well correct?

[@1AAuto]

+trump is your president This manifold will not work for the 5.4, this is specific to the 4.6. In order to see if we have one for the 5.4, you can either provide your vehicles information or take a look on our website 1aauto.com