2000 Ford F150 Harley 5.4

I have a leak coming from the picture below. The housing runs across over to the thermostat and looks like one piece. From what it looks like, it seems like this is going to be a major job.

I am not familiar with what gasket this is. It's on passenger side, and like I said connected to the same housing as the thermostat. Can anyone tell me what gasket this is and how hard it is to replace?

 

That's the coolant crossover on the intake manifold. They were common to leak right where yours is ( from the years 00-02 I believe, then they fixed it), where the metal crossover meets the composite intake manifold. Bad part is, Ive only seen a few temporary fixes that didnt last long. There is no gasket to replace there. The real fix is a new intake manifold.

 

What Toyz said, but I don't see a leak. You have to pin point exact leak before determining a fix. I see nothing leaking in the picture. Could be leaking at the hose for all I know, but I don't know lol. If it's coming from manifold, then it's most likely cracked. Happens all the time, the manifold needs replaced at that point.

 

took the manifold off and there is a piece of the internal plastic that broke. Looks like I can get a new one for about 175 which I thought was pretty cheap... just getting the damn thing off and on that is the pain. Thanks for your help!

 

hey Toyz,

I found the aftermarket replacement Dorman 615-188... when you say you think they had a fix for the problem, what is that? Does the Dorman have the fix. Mine looks like a freak accident... part of the internal plastic housing broke... did they change anything?

Long job, but love the challenge.... getting it out was not easy. Stupid design if you ask me... aside from pulling the engine, everything has to come out! LOL

 

No one has a fix. What Toyz meant is that in 2003 Ford modified composite materials.

It's not a hard job at all and like I said, it's a very common problem. Nothing "freak" about it lol.

Time consuming, -if you haven't done it before, but not difficult.

NOTE: You have to replace intake gaskets. When you do this, you have to prep heads correctly or the gaskets will leak.

 

mine just started the exact same thing today and i was thinkin intake gasket but does the entire intake really have to be replaced? mines leaking from in between the injector and the cast piece the hose is hooked to

 

Sucks , but yes,- the entire intake needs replacement when they crack under the cross over. Plastic welding or Epoxy will not last and is a waste of time.

Some just replace to entire intake with a 99 aluminum set up. There isn't any plastic to worry about then. Ford came out with the plastic intakes in 2000.

 

I just removed a complete intake manifold in good shape off my 2000 5.4 for one of the 99 metal ones...if anyone is interested in it, send me a PM!