97-03 F-150 5.4 Intake Manifold Replacement

Today we have a 2001 Ford F-150 with a 5.4 that is leaking coolant. The leak is coming from the intake manifold itself. We use an updated Dorman part in our repair. This is a faulty common problem on both the 5.4 and 4.6 V8's from Ford in this time frame. This process should be the same on 1997 Ford F-150, 1998 Ford F-150, 1999 Ford F-150, 2000 Ford F-150, 2001 Ford F-150, 2002 Ford F-150, and 2003 Ford F-150 as well as F-250, F-350, Expedition, and Excursion of the same years. F150, F250, F350
Music - Loser Love Song by ‪@hellakidz1898‬ and ‪@independencetunes‬

[@jg-tf1rt]

That seemed smoother than it really was! A testament to your skill and editing..great job!

[@automotiveinsight]

Mostly editing! Thanks.

[@johngeary8534]

Isn’t there an aluminum one from an expedition you can get from ford?

[@72CZPro]

Thank you for your video. My best friend basically donated his old 2001 F150 to my son (his godson) for $250. It leaked like a sieve from the left side of the crossover tube. I tried to remove the tube thinking that there must be a failed gasket, but the it was clear that removal of the tube was not straightforward. I searched the internet until finally coming across your video that pinpointed the EXACT cause of the leak, and unfortunately, it made it clear that the intake manifold must be removed. Your step by step information was excellent. Interestingly, the original manifold that we pulled off today was of the same design as the Dorman replacement that you installed in the video. I ordered the same part. Bottom line, we have busted some knuckles but the truck will soon (hpelyfully) be water tight for about $500 for the manifold coils and various other parts. Thanks!

[@tommynielson125]

How did it go

[@ajpoltz]

I would replace the coolant tube and o rings under the manifold also. Thanks for a good video.

[@Thra5her]

have to pull the water pump.

[@zoharflax6363]

Awesome video, thank you.

[@nickkazynski364]

Great video

[@stevengonyaw1617]

I replaced the intake on my 250 5.4 a couple years ago ! I found the oem intake at a ford dealership for 180 dollars. I didn't want the dormon intake.

[@CITAP1]

While the Dorman intake manifold is apparently the only option available now, I do not consider it a reliable repair. They also went cheap on manufacturing it. Ford is at fault for the original design spacing the bolts at the front right so far apart. They put one bolt on the front of the crossover tube but nothing on the back side. The second bolt is about 5 or 6 inches back by the second injector. How stupid is that. This design will always leak. No fault of the mechanic.

[@jonathanguerrero5844]

I have a 1999 expedition with a 5.4 and I was replacing mine but the new manifold didn’t come with a coolant pipe on the rear of the manifold, have you ran in to this problem or maybe I just ordered the wrong part ?

[@johngeary8534]

When I replaced mine, I installed a JSC catch can.

[@ghettohey2388]

Have a question. I have a 2001 ford superduty with 5.4L V8 2 valve. Im wanting to replace the fuel injector rail. Does anyone know where you can get one of these for my application.

[@missjames385]

Approx how long did it take you to complete the job?

[@michealstone1350]

what is the part number for the upper intake manifold

[@souriwankeobounheuang5680]

Thanks for the video! Can you share the unedited version? If not, it’s ok.

[@automotiveinsight]

After we edit them, we delete everything else.

[@Music32ist]

Where did you get the intake Great Job

[@automotiveinsight]

Rockauto.com

[@johngeary8534]

Just be happy you don’t have the 3 valve..

[@automotiveinsight]

Agreed. The 3 valves are real turds!

[@jamesgo6517]

@@automotiveinsight 04-08 3v ….09-14 brown boot 3v …are pretty fuckin solid with way more power than 2v and no major problems that the rest Modular’s have …timing chain plastic tensioners sorry oil pump ..

[@jaygold4467]

@@jamesgo6517 The 3 valves were real dogs.

[@jamesgo6517]

@@jaygold4467 in a good way for me mf could pull anything out

[@outbacktrek]

[@daredoggo]

I am choosing to do this repair myself instead of paying $3k at the dealership. I am terrified. Will I be able to do it in a weekend? How much other stuff am I going to break while doing this repair because I'm an idiot? Will I forget to put something back deep down in there? I'm sick to my stomach about it.

[@automotiveinsight]

It’s kind of annoying because it’s so far back and under the cowl. If memory serves, there is a vacuum line on the back driver’s side that is kind of hard to get to. You shouldn’t have an issue doing it over the course of a weekend.

[@daredoggo]

@@automotiveinsight I have replaced every single vacuum line under the hood, lol. I'm going for the guts now; the intake manifold. It runs so dang nicely, it baffles me that it's throwing these lean codes. It's being stupid picky.

[@automotiveinsight]

@@daredoggo use a scan tool, watch short term fuel trims, and spray brake cleaner around the intake and all of the vacuum lines. When it start taking fuel away, that’s where your leak is.