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  1. #1
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    Any 5.4 experts out there

    My wife's 2000 5.4 is leaking at the intake. Quick research indicates not a gasket, but a new intake?

    Leaking between the aluminum and plastic?

    What's the most likely issue?
    1963 Marauder S-55, Super Marauder 406
    Only factory 406 powered Marauder, and earliest built Marauder documented to still exist.
    https://sites.google.com/a/wmich.edu/supermarauder/
    ______________________________ _____________

    First retailed 2003 Marauder
    Bought 6 June 2002
    #168

  2. #2
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    Correct. Very very common. A little piece of plastic breaks off underneath and allows the gasket to slip. Dorman makes a better replacement and comes with the gaskets.


    Sent from my iPhone using Tapatalk Pro
    SOLD 12/31/2021

    Cobra short block / ProCharger F1-A / Cog drive upgrade / Manley valves / Brian Tooley Racing valve springs / 80# inj. / -8 fuel line / -6 return / Aeromotive 340 pumps and regulator / 2012 GT500 TR6060 six speed / twin disc clutch / Driveshaft Shop GT500 upgraded CV joint shaft / BA5000 blow thru MAF/ 4.10's / Ford Racing 31 spline set up and Girdle / Metco D.S. safety loop / Stainless Works headers, cats, and everything else out back / ClassGlass hood / Bob's hood strut mod / Hurst line lock / Metco control arms / Addco front and rear sway bars / Monroe severe duty shocks all around / Race concepts rotors / Badgeless grille / 35% tint / FBM's interior LED kit and ambient lighting kit / Pioneer FB700 deck / kenwood speaker 4 Ch. / Rockford Fosgate 10" sub and amp / Kicker 6 X 8's all around / back up cam / bluetooth / Pioneer Xm / 704 RWHP 603 RWTQ tuned by Mo's Speedshop.

  3. #3
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    Quote Originally Posted by justbob View Post
    Correct. Very very common. A little piece of plastic breaks off underneath and allows the gasket to slip. Dorman makes a better replacement and comes with the gaskets.


    Sent from my iPhone using Tapatalk Pro
    I'll second that.

    My 2001 MGM still has the full plastic intake manifold. Behind where the alternator bracket mounts to the intake and right at the temperature sensor I have two cracks. I purchased the new intake but did not have time to put it on so I just used epoxy as a temporary fix. That Dorman intake is really the way to go. They have certainly improved the factory design.

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  4. #4
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    Thanks guys. $200 at Auto Zone and a Saturday should take care of it.
    1963 Marauder S-55, Super Marauder 406
    Only factory 406 powered Marauder, and earliest built Marauder documented to still exist.
    https://sites.google.com/a/wmich.edu/supermarauder/
    ______________________________ _____________

    First retailed 2003 Marauder
    Bought 6 June 2002
    #168

  5. #5
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    Quote Originally Posted by justbob View Post
    Correct. Very very common. A little piece of plastic breaks off underneath and allows the gasket to slip. Dorman makes a better replacement and comes with the gaskets.


    Sent from my iPhone using Tapatalk Pro
    This ^^^

    Quote Originally Posted by kirk View Post
    Thanks guys. $200 at Auto Zone and a Saturday should take care of it.
    And that ^^^

  6. #6
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    Quote Originally Posted by 01MercGMLS View Post
    I'll second that.

    My 2001 MGM still has the full plastic intake manifold. Behind where the alternator bracket mounts to the intake and right at the temperature sensor I have two cracks. I purchased the new intake but did not have time to put it on so I just used epoxy as a temporary fix. That Dorman intake is really the way to go. They have certainly improved the factory design.

    Sent from my SAMSUNG-SM-G930A using Tapatalk

    My 05 GM had the same issues....... I put a P-51 intake on it. LOL
    SEMPER FI From York, Pa

  7. #7
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    Bought a Dorman intake (Autozone Duralast branded) today. Might be a couple of weeks before I can put it on.

    The fact that they had one on the shelf indicates it happens frequently.
    Last edited by kirk; 01-09-2019 at 04:47 PM.
    1963 Marauder S-55, Super Marauder 406
    Only factory 406 powered Marauder, and earliest built Marauder documented to still exist.
    https://sites.google.com/a/wmich.edu/supermarauder/
    ______________________________ _____________

    First retailed 2003 Marauder
    Bought 6 June 2002
    #168

  8. #8
    Join Date
    May 2018
    Location
    Winfield, MO USA
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    43
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    Quote Originally Posted by kirk View Post
    The fact that they had one on the shelf indicates it happens frequently.
    This---^

    That was the same thing I thought when I started doing research on mine. It's utterly shocking when you go to a salvage yard and look at the panther cars. That's where I got my replacement intake and it wasn't hard to find. Actually an original plastic intake would be the hard one to find. All but 2 of the cars there had the Dorman intake and they had TONS of panthers.

    There was a class action law suit against Ford Motor Company about this issue. Not sure what models were included but the last day to file a claim was sometime in 2006. So much for that.

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  9. #9
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    Quote Originally Posted by kirk View Post
    Bought a Dorman intake (Autozone Duralast branded) today. Might be a couple of weeks before I can put it on.

    The fact that they had one on the shelf indicates it happens frequently.


    Worse yet is they stock the $500.00 fuel injection spider assembly for GM’s 4.3 thru 5.7’s too!


    Sent from my iPhone using Tapatalk Pro
    SOLD 12/31/2021

    Cobra short block / ProCharger F1-A / Cog drive upgrade / Manley valves / Brian Tooley Racing valve springs / 80# inj. / -8 fuel line / -6 return / Aeromotive 340 pumps and regulator / 2012 GT500 TR6060 six speed / twin disc clutch / Driveshaft Shop GT500 upgraded CV joint shaft / BA5000 blow thru MAF/ 4.10's / Ford Racing 31 spline set up and Girdle / Metco D.S. safety loop / Stainless Works headers, cats, and everything else out back / ClassGlass hood / Bob's hood strut mod / Hurst line lock / Metco control arms / Addco front and rear sway bars / Monroe severe duty shocks all around / Race concepts rotors / Badgeless grille / 35% tint / FBM's interior LED kit and ambient lighting kit / Pioneer FB700 deck / kenwood speaker 4 Ch. / Rockford Fosgate 10" sub and amp / Kicker 6 X 8's all around / back up cam / bluetooth / Pioneer Xm / 704 RWHP 603 RWTQ tuned by Mo's Speedshop.

  10. #10
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    Ive changed my fair share of injector spiders on the 5.7s on suburbans and tahoes in my day. The cylinders usually fill up with fuel and require you to remove all the plugs and spin it over to get the fuel out. The first time I did one was on my bosses truck and the engine hydro locked after I had it all buttoned up and went to start it. I remember my sphincter was swollen shut til I heard it running actually run I was hoping and praying it didn't bend a rod and was half expecting it to hang a rod out the block.

    The plastic intakes are pretty common here too. In fact there is quite a few that still make it to us with stock plastic intakes.

  11. #11
    Join Date
    Aug 2003
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    A little more help gang

    I got this swapped yesterday/today
    All coils and injectors went in where they came out except that I replaced #5 injector
    Everything back together, started up and out for a test drive and warm up
    Runs great, no visible leaks, except it idles like crap at about 500 RPM

    Throws 3 codes, p1000, p1131, p1151 - lean on 1 & 2

    I cleaned the head surfaces, don't see any obvious issues, all vacuum lines accounted for, torqued per instructions

    2000 Expedition 2WD 174k
    Showing it's age, but is solid and ran well Friday

    Any thoughs?
    1963 Marauder S-55, Super Marauder 406
    Only factory 406 powered Marauder, and earliest built Marauder documented to still exist.
    https://sites.google.com/a/wmich.edu/supermarauder/
    ______________________________ _____________

    First retailed 2003 Marauder
    Bought 6 June 2002
    #168

  12. #12
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    Quote Originally Posted by justbob View Post
    Worse yet is they stock the $500.00 fuel injection spider assembly for GM’s 4.3 thru 5.7’s too!
    Quote Originally Posted by MyBlackBeasts View Post
    That's too funny, I've never seen one fail!
    Quote Originally Posted by justbob View Post
    Seriously? I believe I’ve done four now.
    The poppets are known for sticking wide open causing long delayed starts and cylinder flooding ultimately causing a no start.
    Quote Originally Posted by MyBlackBeasts View Post
    Well I learned something today, good to know.
    With all the 4.3 V6 S10 p/u's, Blazers & Astrovans I've worked on (many with high miles) over all these years, never ran in to it.

    Thanks Bob.
    Quote Originally Posted by decipha View Post
    Ive changed my fair share of injector spiders on the 5.7s on suburbans and tahoes in my day. The cylinders usually fill up with fuel and require you to remove all the plugs and spin it over to get the fuel out. The first time I did one was on my bosses truck and the engine hydro locked after I had it all buttoned up and went to start it. I remember my sphincter was swollen shut til I heard it running actually run I was hoping and praying it didn't bend a rod and was half expecting it to hang a rod out the block.

    The plastic intakes are pretty common here too. In fact there is quite a few that still make it to us with stock plastic intakes.
    WOW!

    Blast from the past!

    My '96 S10 4.3L Vortec ran like a top until about 200K miles.
    Then it started to idle roughly and get really crappy gas mileage.
    Did some research and found out about the bad fuel injection spiders.
    Wasn't going to bother with that mess, so I drove it for another 35,000 miles and sold it.

    BTW: My brother has done the leaking plastic intake (recall) on his 2000 CV.
    2020 Ford Ranger STX DFI Turbo 2.3L 10 speed Auto
    2017 Ford Fusion Sport DFI Twin Turbo 2.7L V6 6 speed Auto (14.000 ET bone stock in 82 degree heat)
    1985 Mustang GT 5.0 Hatchback 4bbl 5 speed manual (525 HP 363 Dart block/AFR heads with Magnum 6 speed in the works)
    1984 Mustang GT 2.3 Turbo Convertible FI. 5 speed manual
    1966 427 Cobra (ERA) 468 all Aluminum FE 2x4bbl 5 speed manual

    SOLD : 2003 Mercury Marauder FI. 4 speed Auto
    w/Crower Cams & Springs, +1mm SS valves, mild port job on the cylinder heads.
    Extrude honed intake w/PHP spacer.
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    'Real Gauges' + matching Trans Temp, Oil Temp, Water Temp, Fuel Pressure, Vacuum/Boost Gauge
    Built: 10/15/02 Bought: 12/16/02 Sold: 10/15/18

  13. #13
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    Any 5.4 experts out there

    I would just go back thru all electrical connections and make sure they are fully clicked on and all vacuum lines, intake boot, and EGR pipe is fully seated. I’m sure it something simple.

    Twice now I’ve had Fords act up because of electrical connections not fully seated. Once an injector, the other was A/C. They seem to be quite picky about being clicked fully.


    Sent from my iPhone using Tapatalk Pro
    SOLD 12/31/2021

    Cobra short block / ProCharger F1-A / Cog drive upgrade / Manley valves / Brian Tooley Racing valve springs / 80# inj. / -8 fuel line / -6 return / Aeromotive 340 pumps and regulator / 2012 GT500 TR6060 six speed / twin disc clutch / Driveshaft Shop GT500 upgraded CV joint shaft / BA5000 blow thru MAF/ 4.10's / Ford Racing 31 spline set up and Girdle / Metco D.S. safety loop / Stainless Works headers, cats, and everything else out back / ClassGlass hood / Bob's hood strut mod / Hurst line lock / Metco control arms / Addco front and rear sway bars / Monroe severe duty shocks all around / Race concepts rotors / Badgeless grille / 35% tint / FBM's interior LED kit and ambient lighting kit / Pioneer FB700 deck / kenwood speaker 4 Ch. / Rockford Fosgate 10" sub and amp / Kicker 6 X 8's all around / back up cam / bluetooth / Pioneer Xm / 704 RWHP 603 RWTQ tuned by Mo's Speedshop.

  14. #14
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    kirk, did you put RTV in the dimples at the 4 corners?
    The Blackbird
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  15. #15
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    Quote Originally Posted by RF Overlord View Post
    kirk, did you put RTV in the dimples at the 4 corners?
    Don't know what you're referring to? No RTV, unit comes with seals.

    Could be I should have replaced a couple more injectors.
    1963 Marauder S-55, Super Marauder 406
    Only factory 406 powered Marauder, and earliest built Marauder documented to still exist.
    https://sites.google.com/a/wmich.edu/supermarauder/
    ______________________________ _____________

    First retailed 2003 Marauder
    Bought 6 June 2002
    #168

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