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Personally I prefer the crown vic tube and ditching the satc cold lockout (heater cold auto on sensor)
 

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The Explorer tube is basically the Mustang tube with an extra branch for the water PCV heater. I used that tube last time around and just plugged that branch. Before that I used the Crown Vic tube. No real preference for either, as both require a certain level of creativity to hook up cleanly, I deleted CELO on both setups.
 

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i don't think my cold lockout even works, but i left it in by cutting it off the old tube, flaring it on both ends, then splicing it into the hose i used to connect the PI tube to the heater core. figured it was in their before, why not leave it :D still blows cold air on my feet in the winter. 'shrug'

neat, my thread is listed in their at the bottom of the definitive PI swap link! i feel special :D
 

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i don't think my cold lockout even works, but i left it in by cutting it off the old tube, flaring it on both ends, then splicing it into the hose i used to connect the PI tube to the heater core. figured it was in their before, why not leave it :D still blows cold air on my feet in the winter. 'shrug'
So, how did you make the ground connection?

On the 5.0HO, it's completed through the bolt that holds that tube to the intake.

If that tube is just floating in rubber, you need to provide a ground return for that switch.

RwP
 

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I have built brass Tee's for the sensor and welded a brass bolt to one side to ground it then use hose barbs for the heater hose. Probably more complicated than most want but it is trouble free.
Alan
 

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Iv got my factory Intake off and went to fit the explorer one and it seems to be In the way of the the coolant tube / water pump nipple. Do I have to take out the plugs In the intake for the tube to run threw or get a different coolant tube?
 

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Seems my water pump nipple hits this center hole, do you remove that? This intake also had like a bigger foam tampon on it that I slide off also.
I have a 95 coolant tube, 96 coolant tube and 04 explorer one that came with this intake because I pulled it off the engine myself. I didn't try all the tubes yet
 

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The pi tube makes a hard turn right after the nipple the pipe is not straight through.
I actually built my own tube and threaded the block for a hose barb fitting, but I have a trick flow intake.
Alan
 

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Discussion Starter #31


Seems my water pump nipple hits this center hole, do you remove that? This intake also had like a bigger foam tampon on it that I slide off also.
I have a 95 coolant tube, 96 coolant tube and 04 explorer one that came with this intake because I pulled it off the engine myself. I didn't try all the tubes yet
Remove that "hole" if that's even possible, and you'll be drawing air in through there.

You have to use a PI coolant tube and water pump nipple. Plain and simple. Otherwise, how are you going to install the PI intake?? Look through all the threads in the link in the very first post. Nothing has changed since 10 years ago when people started doing this. You're making this difficult when it doesn't have to be at all.
 

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PI intake "definitive" article Q's

I'm going to do the upgrade and want to make sure I've ordered/gathered every last part I need and that they'll fit properly (exception being the gaskets, requiring RTV) so I can do this quickly in one fell swoop.

I read through the compilation of threads/posts in the go-to "tech article" (yes, all of them). It would be more helpful crafted into actual articles, with different years getting their own treatment since the procedures and needs differ.
As is, with practically every search return that mentions a PI Intake being lumped together, there are so many posts in those threads that go off on tangents as to make it a PITA to get at the meat.

... Which may be why, after reading so much irrelevance, I have now forgotten the following, if it was actually in there:

1. Exactly what hardline heater tube do I need? I think someone in those posts said the stang won't fit my car, but the Explorer one will? What vehicle do I go hunting up a part number for? Is the part # the same across all 2V PI vehicles? I prefer to use the hard line instead of pressing my luck with several soft (at least one 90°) hoses.

2. Exactly what nipple/bypass do I need? Again, will the stang (and which years) fit or do I go hunting for a Crown Vic or Explorer part? I don't recall seeing an actual part # in those threads.

3. At 88k, would my water pump o-ring be good to go back in? Anybody had issues reusing their original?

4. As my original intake was replaced with the recall, I have the 2-sensor aluminum crossover, so I'll swap it over. Are the PI crossover o-rings an exact match for the NPI crossover o-rings? Sure, you can swap the crossovers, but there could be slight differences. Has anyone had probs later on from using the PI o-rings with the NPI crossover? I don't recall seeing this addressed. I guess if there's a chance of problems down the road, I can tap the PI crossover instead.

5. The PI intake itself is different among vehicles. This helpful video shows a PI intake taken from an Explorer, requiring a heater line mod (I set the start time to the relevant segment):


... whereas the one on Amazon, et al, seems to have a port ready to slip a hose onto: http://www.amazon.com/Ford-Racing-M9424P46-Intake-Manifold/dp/B000CNHT0E/ref=sr_1_1?ie=UTF8&qid=1396727806&sr=8-1&keywords=4.6l+pi+intake
I take it the Amazon one is the exact version I need for the Tbird.

6. The recommended RTV in the compilation of posts was Ultra Black. But people have since recommended to me red RTV. Has the consensus changed? Is red preferred over Ultra Black now?
 

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1. Exactly what hardline heater tube do I need? I think someone in those posts said the stang won't fit my car, but the Explorer one will? What vehicle do I go hunting up a part number for? Is the part # the same across all 2V PI vehicles? I prefer to use the hard line instead of pressing my luck with several soft (at least one 90°) hoses.

Ford part number xr3z-18b402-aa

2. Exactly what nipple/bypass do I need? Again, will the stang (and which years) fit or do I go hunting for a Crown Vic or Explorer part? I don't recall seeing an actual part # in those threads.

Ford part number f75z-8555-aa

3. At 88k, would my water pump o-ring be good to go back in? Anybody had issues reusing their original?

I would just replace the water pump while your there. They usually come with a new gasket ring. 88k miles and your there. .

4. As my original intake was replaced with the recall, I have the 2-sensor aluminum crossover, so I'll swap it over. Are the PI crossover o-rings an exact match for the NPI crossover o-rings? Sure, you can swap the crossovers, but there could be slight differences. Has anyone had probs later on from using the PI o-rings with the NPI crossover? I don't recall seeing this addressed. I guess if there's a chance of problems down the road, I can tap the PI crossover instead.

Drill and tap it. I've tried to change the crossover and had it leak. You can't find those o-rings anywhere, at least I can't find em.

5. The PI intake itself is different among vehicles. This helpful video shows a PI intake taken from an Explorer, requiring a heater line mod (I set the start time to the relevant segment):

I always use either Crown Vic (or any panther chassis) or Mustang intakes.

6. The recommended RTV in the compilation of posts was Ultra Black. But people have since recommended to me red RTV. Has the consensus changed? Is red preferred over Ultra Black now?

Having done the intake only swap on about 10 cars (2 mine) I have used only the red RTV. Never had it leak.
 

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hello I have gotten my intake and gaskets as well as the heater tube from Blue Oval Chips. I went with the 01 mustang water pump and o ring. I replaced it when I started the swap when I took off the water pump pully I noticed the shaft was leaking so it was a bonus. but if you feel like you need to replace it while your there for a peace of mind it is understandable. the main reason why I got my intake from them was to make sure I got the right things in one full swoop the extra alt braket is a good thing. but the tube and the second sensor hole drilled is a good thing as well
 

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I agree with everything stay_unique_91 posted.

I've done two so far, and didn't have leakage issues using ultra black; either will work. As long as it's "high temperature RTV" is should work for this.

The hardline tube is different on the explorer, and the heater core outlet is on the front somewhere; I've never used those.

You will have to do some adaptation of cooling lines at the back; while you have all this out, look into adding one of the cooling mods for the driver's head.

Tapping the manifold isn't hard; the drill and tap can be had for $20. I'd see if a machine shop would do it for $10, lol.
 

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Thanks folks. I think I have an almost full tube of red here, but it's really old, so I dunno that I trust it, even though it SEEMS good. Does this even have a shelf life?

The guy in that video is using white silicone caulk; not sure what the temp rating is on that stuff.

while you have all this out, look into adding one of the cooling mods for the driver's head.
Are you referring to dropping in a 180° t-stat? I was planning on replacing the t-stat, but would the 180° cause cat & emissions probs (e.g., inspection failure this coming October)? I could swap it back just before inspection I suppose, but what about MPG with the 180°? I read that dropping temp hurts fuel economy and screws with the cats & emissions but can ultimately boost HP a little.

What other mods did you mean?
 

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Ford part number xr3z-18b402-aa
Ford part number f75z-8555-aa
Thanks! Now all I need are gasket numbers, since I forgot to mention those. I can find 'em in online catalogs for the stangs I reckon -- I assume THESE are at least the same for all 4.6L 2V PI's?

You can't find those o-rings anywhere, at least I can't find em.
According to the YT comments for that video, the part #'s are 5W7Z-8C387-AA and 5W7Z-8C388-AA. They are available online from a number of suppliers.
However, nothing was said about these fitting better than the ones supplied with a new PI intake. They may just be NPI o-rings -- or PI as well, if both take the same part number. :zdunno:

@95mercxr7:
Thanks, but I saw the Blue Oval kit earlier and I can do better pricewise by collecting the individual parts myself.
I already have the alternator bracket from the stealership recall replacement, so I don't need that. The BO crossover doesn't appear to have the 2nd sensor location drilled, either, so I'd still have to deal with that issue.
 

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what is mentioned is the part number for the coolent tube stay unique mentioned gets bolted up to the left head.

the new nipple you would have to tap out and tap in the new one so the new tube can be put in.

I just wish I did pics to post to show you what you have to do with that.

I hope some one else can chime in on that aspect.

the only thing I had to do like with others is have a longer heater hose one of them is the regular length but the other is a little longer to reach.

mine is a little different because I had to get a lot more for mine like extra vacume hoses.

I had a different intake manifold on my first gen 4.6.

if you try to put on the pi intake the old coolent tube will be in the way.
 

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argh!

I've ordered the manifold. I have some Q's regarding other components before I order them.

1. Pump o-ring and gasket or one and the same??

The water pump o-ring is part F1VY-8507-A, correct? Yes, I know a new one should come with a new pump, in which case I wouldn't need to worry about that particular part, but in any case...

The parts catalog shows this part to be not an o-ring but a cut gasket that goes between the pump housing flat and the block. However, as seen at 16:30 in the video in post #1, there is clearly no such gasket present when the original pump is removed, indicating Ford didn't use the gasket on these cars.

As seen here it comes back as "SEAL-4.0 I.D. O RIN", clearly indicating it is an o-ring. The price is exactly the same as the gasket, which would lead one to believe the o-ring is the gasket and vice-versa, despite the pic: #3 doesn't look like an o-ring, now does it?
It's not just AutoNation, either. Fordparts.com catalog shows the same gasket (at 5x the AutoNation MSRP!): WTF??

FFS, is there a secondary gasket on these cars or not? If the factory didn't install these, why does the official parts catalog show one (instead of an inner o-ring)? And for that matter, why isn't the o-ring shown in the catalog, since it obviously does go on the car (as seen in the video) and can obviously be ordered via unique part number (assuming the part number is not actually for the cut gasket)? :bangwall:

I don't want to yank the pump and [possibly] damage a [possibly existing] secondary gasket and then regret not having ordered a replacement ahead of time. And, I want to make sure I'm ordering the correct part(s) if I decide to reinstall the old pump instead of a new one (in which case I'll want a new o-ring at least), and if I buy a new pump I'll [maybe/likely] want a new cut gasket on hand.

2. Thermostat o-ring.
I wonder what vehicle this fits (check their I.D.). :crazy:

Here we go again. Fordparts.com is showing an o-ring, although they refer to it as a gasket, and the exploded diagram shows a cut gasket for the housing instead of an o-ring. :bangwall:

At least the two suppliers' MSRP's agree on this part.

At 13:35 in the video, he mentions the o-ring and there's [again] clearly no housing gasket present.

So, is that the correct part number, despite AutoNation's I.D. spec and it being shown as a cut gasket instead of an o-ring in [portions of] the parts catalog(s)?

3. Fel-Pro vs. OEM PI intake gaskets.
Note I said I'll be using PI gaskets, not NPI ones, so this concerns only the PI versions, as those are the only ones I'm interested in.

Do the OEM ones have a metal or composite layer sandwiched in, making them superior and thus accounting for one OEM being the price of the entire Fel-Pro set, or is it just the usual price gouging because of it being OEM?

I don't want to cheap out and experience a leak anytime soon. BUT, if the Fel-Pro is just as reliable as OEM, then I don't mind spending half (or less), either.

Also, at 28:30 in the video he says there are two different replacement gaskets, but doesn't that only apply to [some] non-OEM ones? The OEM PI gasket can be used on either side, because the extra seal ring can be used on the front (t-stat) and back (heater nipple) by simply orienting them properly, so that one OEM gasket part number (YL3Z-9439-BA) is used on both sides, correct?



re: crackpipe mod
I'm not sure I'll have room at the back of the head to work, but I'll look into it. I'm certainly not about to hack on a brand new PI plastic intake, though, as here.

re: others
I'm staying with stock t-stat rating. Not gonna do a cobra rad mod, either. I have other things to spend time and money on, so I'm a dud for now. :tongue:
 

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1. Pump o-ring and gasket or one and the same??
There's an o-ring that seals in the bore in the engine block.
There is no other gasket.
I've replaced several, NPI and PI.

BTW, Get the later water pump with the anti-cavitation rotor. :)


2. Thermostat o-ring.
There is an oring that goes between the cap and thermostat; that's it.

3. Fel-Pro vs. OEM PI intake gaskets.

Do the OEM ones have a metal or composite layer sandwiched in, making them superior and thus accounting for one OEM being the price of the entire Fel-Pro set, or is it just the usual price gouging because of it being OEM?
There's no metal layer in the stock intake manifold gasket.
I've used both types, and never noticed a difference.

re: crackpipe mod
I'm not sure I'll have room at the back of the head to work, but I'll look into it. I'm certainly not about to hack on a brand new PI plastic intake, though, as here.
This is what it looks like; you have to knock out a freeze plug, and put in two bolts to install it; the part needs a hacksaw cut first, and you have to make a small bracket to hold the other side. :)
One exists that has a bung for the Sensor for the automatic heat controls. Ther was no part number on it, tho.


 
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