2000-2014 Ford 5.4L E series intake manifold replacement

How to fix it with a Dorman 5.4 Triton intake manifold on a Ford van. Removal and installation. should be the same for all E-150, E-250, E-350, and E-450 vans. This was a 2003 E350. Econoline, Club wagon, Cube van, Super Duty. This intake manifold also fits in the Ford Excursion, Expedition, F-150, F-250, F-350.
e150 e250 e450 f150 f250 f350 e f 150 250 350 450 2001 2002 2003 2004 2005 2006 207 2008 2009 2010 2011 2012 2013 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14. removal. fix
Disclaimer:
Due to factors beyond the control of Rust Belt Auto, it cannot guarantee against unauthorized modifications of this information, or improper use of this information. Rust Belt Auto assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this video at your own risk. Rust Belt Auto recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video. Due to factors beyond the control of Rust Belt Auto, No information contained in this video shall create any express or implied warranty or guarantee of any particular result. Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained.

[@ZZZRSC]

This is a great video and the only one on KZbin that has clear, detailed information (including wrench sizes) on the steps to remove and replace the manifold on a Ford Van. I need to do one on an E250 1998 with an aluminum upper and a plastic lower. Maybe just needs gaskets. I was worried about what was involved, but I feel more confident now.

[@paratour2016]

I have a 2006 E350 5.4 ( 235k miles) leaking coolant at the intake manifold. I am very thankful to have found this video. Super informative and entertaining. Great edit on the slow motion flying wrench! 😂

[@calixcris9144]

Thank you for this video man! Gave me the courage to tackle this repair on my 07 Ford e350 XLT. Granted it took me a day and a half (didn’t have all of the right tools) but it got done 😀

[@RustBeltAuto]

🍪. emoji cookie for you!

[@andrewk778]

A Dorman manifold?!?! You have guts. A good job to take photos before starting. Thank you for sharing.

[@hummertim1]

This guy rocks very helpful. I was able to do my own intake on 2001 ford e250 v8 5.4 van very easy to do. just takes hours to disassembling it. Then it takes hours to reassemble properly not a rush job at all. Be patient dont rush or costly mistakes happen.

[@brianmatthysse7565]

Great video thank you I watched your video and changed out my own 2004 E350 and it was successful, just followed your instructions good job. Much appreciated.

[@yes-ib9tm]

As one who has to do this soon let me quote Bette Midler by saying: "Did you even know that you're my hero, and everything I would like to be?.. You are the wind beneath my wings." Hopefully it won't blow up - love it. I'm hopeful my goes this easy. Thanks for the vid.

[@RustBeltAuto]

Thanks!

[@Sebi076]

Thanks for saying all the measurements on about every nut and bolt!

[@steved7563]

Glad no one in my circle has a van, those 5.4's in a truck are fun enough, nice how the time lapse hides the cursing

[@fsu3784]

I thought it was easier in the van compared to the truck. Getting to the back of it is great.

[@WizzRacing]

Best Econoline video I ever seen. On replacing the Intake gaskets. I been putting mine off for 3 years. But cost of gas is getting to high again. To let it go anymore... Thank God I have the metal intake on my 1998...Just need to replace the intake gaskets. As they leak on me...

[@yerbusiness]

Thanks. Very well done. It's hard to find anyone that will go to the lengths of doing the job right, these days. Everyone wants to shortcut this or that, and sometimes it's ok, but many times, it isn't. Sure helped me, you did.

[@RustBeltAuto]

Welcome!

[@joemcgrath5106]

Yooo, great video! Walked me right through a successful procedure. Man what a job, my shoulders were jelly like after a serious workout.

[@marcsmith3881]

Great video. I have done plenty on the older Expeditions, but did the first 2012 E250 4.6 intake manifold today. I agree with you, it is easier to do in the vans although the 4.6 is tougher because the intake part where the throttle body bolts is not removable. Definitely tighter to get out because its taller. I had coolant in 3 spark plugs near the jackets so it had to go. The bolt near cylinder #3 broke., but was nice enough to leave a 1/4" sticking up. 2 hours of PB blaster and I finally spun it out.

[@florenbaron7111]

Please list the symptoms you had. I would really appreciate this.

[@watchmanonthewallcouk6498]

Thank you Sir, armed with your video I’m tackling my 04 e250! Hopefully I won’t burn it down to the ground 👍

[@RustBeltAuto]

What's the downside?

[@omarmcusa]

THANK YOU!!! Your video is very informative, I will attempt to replace the gaskets myself in the morning.

[@JoshInYaa]

You're hilarious bud! Made me laugh so many times... one of my favs "the instructions say to go to 3nm, which is about nothing" Thanks for the video, keep up the good work!

[@RustBeltAuto]

Thanks! I don't try to be funny. When I was a kid, I knew I was funny when I got punched in the face.

[@JoshInYaa]

@@RustBeltAuto fellow mechanics like myself feel your pain and the tidbits of dry humor cause we all know how much working on cars can suck. Soon as I saw you were doing a van all I could think was... Mmmmm thats gonna be funnnnn about the same time you said it.

[@WJdad]

There is a 2000 ford Econoline satellite van for sale. It’s too cheap. Figured it has a problem and wanted to know what to look for. Online research showed the plastic intake manifold was listed as a common repair for coolant leaks. Thanks for showing how that may appear up front. Ended up watching the whole video, mostly because of your humor and the well made video. Speeding up the repetitive stuff is awesome. Thank you!

[@Gotdurt]

And I'm going to add "destruction manual" to my vocabulary.

[@biggiefitz6275]

The 5.4 Triton 3v makes a GREAT anchor for a big boat on the other hand.

[@RustBeltAuto]

I prefer fluke anchors. They work much better, and have a weight savings of a few hundred pounds. They really don't make good boat anchors, but in a pinch, I'm sure you could use one.

[@johnnymac1580]

Excellent, thank you, for the detailed information ⚡️

[@brittharms978]

Your bad assss!!! Great work!!! Vans are a challenging to work on!

[@clementemotto7588]

Really good explanation love the way you work I have two Van's just like that thanks

[@tedthornton7791]

When I replaced the cylinder head temp sensor under intake. It was a beel cha. 😢 Them hoses , electrical connections, and that hold down strap on the back socks. I used the Fel-Pro intake gasket kit. I had to remove and reinstall the injectors three times. Oh boy that was hilarious let tell ya. Apparently the o rings in the kit wouldn't seal. Eventually reused old ones. What do ya know they sealed. This is my nephew's 04 F150 5 .4 Lariat. Done under a shade tree in the Back yard in 95 + heat. I became addicted to Gatorade and Pepsi. Lol

[@MrLeo92335]

Great video man, you just showed me the gates of the hell I'm gonna have to go thru, lol, I have to do this and I'm a truck driver lol,,,thanks

[@dominicpacione393]

Love his videos. His ram 1500 diff rebuild one was good to!!

[@TheWallyjp]

These are not too bad to do... I have done a handful of them.

[@deezdrama]

Its hard to find good E-series info... This gives me hope. I have a 2002 e350 with the 6.8 v10. I bought it and it had a severe timing issue. I found out after weeks of throwing parts at it that the crank position trigger wheel was broke.... After a topend and front tear down and replacing the trigger wheel, and timing chains, tensioners,coils, plugs, and every sensor on the damn thing I had a strong running van for about a year. Then out of the blue I got the dreaded broke rocker tap. Using a stethoscope I pinpointed the tapping to the backside of the passenger head. The problem is when I did timing chains I could not get that valve/cam cover off for the life of me, there just wasnt room. Do you think if I remove the intake I will have room to remove the cover? The 6.8 ive read is identical to the 5.4 just 2 extra cylinders. My van has sat for over a year and am debating if I should junk/sell it or attempt to get the cam cover off, I dont want to have to raise the body. Thanks...Great video!

[@RustBeltAuto]

I don't know.

[@ThomasFerner]

Great vid...Only thing I would say is Go with OEM manifold...Yes WAY more expensive but there's a reason for it .

[@RustBeltAuto]

What's the reason? Inquiring minds want to know.

[@DavidBrooksNYC]

hey man thanks for posting, your videos are solid !!

[@zimrimayfield]

Awesome video, thanks so much for all your hard work and effort to show us : ) I just bought a 2002 Ford E150, and I need to check the IMRC to see if the plastic bushings are broken. Do you know if I can access (even just feel with my fingers) the IMRC without removing too much, and where to access it from? Thanks so much regardless of your answer : )

[@RustBeltAuto]

I dont know

[@florenbaron7111]

After a lot of troubleshooting and research, I think I have a similar problem but coolant is also being sucked into the combustion chamber. From your experience, is it likely coolant is being sucked into the combustion chamber? Steam is coming out of my exhaust pipe. I don't think it's a blown head gasket. My spark plug wells do seem to have coolant in them. Also, when I first turn on the 2008 Ford Econoline E250 V8 4.6 2 valve, after the van sits foe awhile, steam comes out of the exhaust pipe a lot more but then reduces. I have no DTCs. I had to replace the water pump. Now there is preasure in the coolant system but I am still loosing coolant somewhere. My engine only shakes after the engine warms up. My coolant guage is not working but my scan tool shows the temperature. That van seemingly only has a cylinder head temperature sensor, not a typical coolant temperature sensor. The vehicle barely moves when pressing the gas. I appreciate you sharing your experience with us. Thank you.

[@RustBeltAuto]

There is a seperate sensor for the gauge. I would do a block test on that.

[@FUNKBOOGIE1]

Rust Belt Auto ? on the 2000 Ford e350 5.4L, under the dog house on the passenger side at the end of the intake manifold why is there open holes with gasket sticking out ? is something missing ? can something fall in those holes and damage engine ?

[@Lex-qr4cp]

A useful video though I hope I'll never need it. Thanks.

[@MozerDozer404]

Thank you so much for the upload

[@brettbothe4979]

Great Video, are the gaskets that come with the new part sufficient? Or do I also need the gaskets that are all linked together?

[@RustBeltAuto]

You only need one set

[@infinity3jif]

doing valve cover gaskets on this thing must be hell

[@kar15bigdog]

I wish I could do all that but it looks like a lot of work ... I have the same issue in my van E150 2006 .. I'm wondering how much I have to spend

[@hummertim1]

1000.00 + with extras expect to buy a new intake manifold because it will be the problem deterated. Mine was

[@jaybedford6148]

Thanks for the video. Let's me know I better hire a professional to do this! Lol

[@Brian-bg2cb]

Thanks!

[@BarnStangz]

YO! When you yelled "HELLO" into the intake, did you hear anything back? Did you hear the sweet, sweet, sounds of the ocean? Dude, that was a pretty intense job! How many hours you got into that piece? OKAY BYE!

[@RustBeltAuto]

I didn't count.

[@BarnStangz]

Dude, you need to yell into the next intake! Did you see my message on your goofy community tab!?

[@sbutonable]

Great video

[@johnnymac1580]

I have had my E150 for 22 years, but I guess it’s a Ford van⚡️

[@oggarage3459]

Great video thanks, could this be the problem with my 05 van am getting codes p0171 and p0174 lean both banks

[@RustBeltAuto]

Lean bank usually indicates intake leak. If you have a scan tool, you can hose the intake down with flammable brake cleaner, when it's running, and see if the fuel trim goes negative to find the leak.

[@oggarage3459]

@Rust Belt Auto I do have a scanner, I will try that, thanks.

[@iwasmadeforthenomadlife443]

Sir, can you put a list of the tools you used in this video? there are a couple that I do not know what they are called. There is a tool you used to pull a hose off, it was right after you said that you disconnected the negative terminal, At the 2:14 mark.Thank you

[@RustBeltAuto]

@@iwasmadeforthenomadlife443 probably a long reach hose pliers. There is a set of 3 of those.

[@iwasmadeforthenomadlife443]

@RustBeltAuto thank you. Amazing video by the way. I'm a 61yr old woman, not mechanically inclined, but I feel pretty confident that I can do this watching your video. May take me a while, but no hurries.

[@RustBeltAuto]

@@iwasmadeforthenomadlife443 good luck!

[@iwasmadeforthenomadlife443]

@@RustBeltAuto thank you.. I'll need it.

[@randyaivaz3356]

Hope you can help, was test driving 2013 E250, 4.6, after a transmission sensor underneath. Then it sounded like Big exhaust leak, it is Puffing Hot Air out of Right rear on appears to be on the Black Plastic Manifold. Would think exhaust. May be metal but tapping it sounds like plastic. Thanks, Good Video Stratmando

[@RustBeltAuto]

It is probably a leaking egr pipe. There is a silicone seal on the manifold for that.

[@randyaivaz3356]

Hey Thanks, will take a look, just couldn't see.

[@grad0n]

So a buddy just asked me to replace his valve cover gaskets. He mentioned the engine mounts have to be removed and engine lowered in order to get them off. Do you know if the intake manifold can stay on?

[@RustBeltAuto]

I don't know.

[@andyperez8308]

why did you have to replace the whole manifold instead of just putting new seals in if it leaked?

[@RustBeltAuto]

You must remove it, and look for corrosion. If the manifold is leaking from corrosion, the manifold will need to be replaced. So it depends.

[@arnaudmessier3584]

thanks for your video ! great help. any idea of the part number for the hose that goes to the ac/fuel pressure reg/egr solenoid/throttle body ^ mine broke into pieces when i pulled it thanks

[@RustBeltAuto]

I do not, and usually take a piece to the parts store, an find flexible hose the fits it nice, and use that.

[@LatvjuAvs]

What a joyride to change it.

[@ramsesvelasco]

My E350 just showed the same symptom on the left side under the heater core hose connection ... for a moment I thought I could just take off the aluminun crossover pipe turns out the whole manifold intake has to come off , anyone in LA knows experts like Rust Bel Auto ? ... I got the skills but not the memory to plug everything back 😁

[@StrawberryCowboy]

Same here. I wanna try and do this myself but I'd forget immediately where to plug everything back in

[@iwasmadeforthenomadlife443]

someone told me to take pics and vids of everything.

[@iwasmadeforthenomadlife443]

@@StrawberryCowboy someone told me to take pics and vids of everything.

[@TonyYesi]

I wish they made metal intakes for the Fords.

[@watchmanonthewallcouk6498]

Fantastic, thank you !!

[@RustBeltAuto]

Welcome!

[@RayLitchmore]

My van has a metal pipe to heat up coolant or throttle body, coming out from the manifold, passenger side. It’s rotted and leaking. Any way to fix or bypass?

[@RustBeltAuto]

Can you cut out the bad spot, and use a piece of hose?

[@RayLitchmore]

@@RustBeltAuto wish I could show you a picture of it. I would do anything to stop the leak. It has 2 hoses and PCV line connected to it.

[@RustBeltAuto]

@@RayLitchmore i would think you can buy that mess of plumbing.

[@Gotdurt]

I have a bad coolant leak coming from the valley of my E150 4.6... Everything I'm reading points to these plastic intake manifolds, BUT... mine isn't plastic, it's aluminum. Even when I look up the replacement manifold, the plastic ones are spec'd. Don't know what to think now...

[@RustBeltAuto]

Probably intake gasket, or thermostat housing/hose leak.

[@Gotdurt]

@@RustBeltAuto Didn't think to look toward the front for the leak; looks like it's coming from the heater tube where it enters the back of the water pump. I can *almost* access it... but not quite. Guess the intake is coming off 😕

[@George-fd1zx]

What would be a fair price to charge to do a job like you just did I'm doing a 06 e150 van what would be a fair labor price please tell me

[@George-fd1zx]

What would be a fair price to charge to do a job like you just did I'm doing an '06 F-150 e150 I'm sorry intake manifold replacement

[@RustBeltAuto]

I don't know.

[@FUNKBOOGIE1]

Rust Belt Auto ? Whats the going price to have a intake manifold replaced on this van ?

[@RustBeltAuto]

I don't know.

[@vladimirhernandez8682]

Gracias BENDICIONES

[@biggmike04]

Can you redo this video and I fast forward it so I can see where all the wiring harnesses and Plus go to

[@hectorotani27]

Howdy ,does it matter if new one is not as tall or has that bigger belly as old one?

[@RustBeltAuto]

I don't know what you mean exactly, but probably not, if it fits.

[@hectorotani27]

@@RustBeltAuto look at bottom of old one it has a larger hump and new one dont I think it's probably a redesign

[@hectorotani27]

@@RustBeltAuto ya if u put them side by side new one sits lower , i think im just gonna send it ,thanks for responding and great vid!!

[@RustBeltAuto]

@@hectorotani27 is it Dorman, or something? A lot of them are universal.

[@hectorotani27]

@@RustBeltAuto I just found out it's a heat shield and to keep it less noisy ,so it's not requiered

[@oxygencarbon3331]

What that funk thing name you are using to pull out the hose?

[@oxygencarbon3331]

Can we find it anywhere in the shop?

[@RustBeltAuto]

Extrapolate please.

[@fuckfaceunstoppable4052]

It was a fuel line disconnect tool. Most parts stores Have them

[@hardywhite1774]

Where does the throttle body coolant line out go to and attach

[@RustBeltAuto]

Keep looking.

[@jonathanvelasquez6571]

Thank you...

[@RustBeltAuto]

Welcome...

[@Brian-bg2cb]

I gotta say this was a HUGE help! I had to get my 2000 5.4L E-250 back on the road. it was leaking coolant for the longest time and I changed out the sediment filled radiator and heater core, heater fan motor and bottom octopus hoses, top hose, thermostat (put the O-ring on the bottom instead of the top... it was leaking), coolant reservoir, and of course, the 40 pound stock intake that had the "under valley" filled with coolant that was "mysteriously" draining out of the reservoir through the notorious plastic crack without the engine running. I could make short runs but I had to take some water with me so I could make it back home. Finally got it all together after I figured out where the brake booster vac hose was really supposed to go. No check engine light and it runs just like this: kzbin.info/www/bejne/eH60ZHmmh52Wb5Y Excellent coverage and language. Thanks a Bunch!!!!

[@zaynehm2444]

I didn't see that you put silicone before you placing the manifold ?!? I think the 4.6 i$ harder then 5.4

[@RustBeltAuto]

Where do you think I was supposed to have put silicone?

[@WizzRacing]

There is no silicone. They gasket has them built-in... You might mean Anti-Seize.... And having done Trucks.. I would rather do the van...You can get your hands on shit in the rear...Without having to get on top of the engine with a damn pillow. To get at them brackets in the rear....

[@RustBeltAuto]

@@WizzRacing Did I silicone something? I can't remember this job.

[@WizzRacing]

@@RustBeltAuto No..But people try to fix them leaks around the thermostat housing with silicone..Never going to happen... You have to replace that plastic intake and the gaskets. To fix it for good.. Why I'm glad My 1998 E-150 had an all aluminum intake..But them gaskets will leak over time,. Then you get the dreaded 0171 0174 codes...

[@pepitofeliz7862]

What dose a shop charge for this job

[@RustBeltAuto]

I don't know

[@biggmike04]

I like the video but can you not fast forward it at the end

[@acihawaii]

Is this a reliable work van ?

[@RustBeltAuto]

Yes

[@FA-sr6lx]

How long did this take you without speeding it up

[@RustBeltAuto]

Woke up. Did the job. Was done sometime before I went to sleep.

[@FA-sr6lx]

@@RustBeltAuto wow so a whole day worth of work. I have to do this too and replace the spark plug gaskets and valve gasket. 😱

[@RustBeltAuto]

@@FA-sr6lx I don't know what book time is on this. I did not take me a whole day. I just used one.

[@WizzRacing]

@@RustBeltAuto Book time says 11 hours...Basically $1200.00 labor at the dealer...

[@mediaguy4037]

@@RustBeltAuto Woke up, had your coffee eggs and toast, and then did the job.

[@NN-cw9rb]

thumbs up just for the burn it down comment hahaha

[@ricrogers1383]

Wth do all that for the intake? That's insane...

[@RustBeltAuto]

You should try to take one off a WRX.

[@ConfidenceOkagbo]

Timing setting

[@RustBeltAuto]

Timing? Whatcumean?

[@JDIVINE144]

WOW I

[@demingo030375]

Do you have your own shop? Where you located? I like for you to work on my van

[@RustBeltAuto]

I have a virtual reality, and live in outer space.

[@demingo030375]

@@RustBeltAuto wow

[@RustBeltAuto]

@@demingo030375 😂

[@mediaguy4037]

It's not even a hole.

[@RustBeltAuto]

It was kind of a hole.

[@CenobiteBeldar]

God damn this looks like a headache.

[@tekksavvy1374]

!