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How do you replace upper intake gaskets on 1996 ford explorer?
Wiki User
∙ 15y ago
I'm assuming that you have the 5.0 302...
First and most important step is to go to Pep Boys/Autozone/Advance Auto and get the Haynes repair manual for $20. It has pic and most importantly explains that you'll have to loosen/retighten all of the intake manifold bolts in a specific order and how you'll have to lean the manifold forward to get the rear-most bolt out.
You'll have to remove the air cleaner, throttle cables, coils, an. Please label all plug wires before starting the disconnect. Be very careful removing the plastic clip to the right and rear of the coils. i broke mine and the parts guy couldn't find it or a part number on his diagram. Luckily there was an older dude there that said that it was a fuel line clip, which only happened to come in the box with the fuel filter. He told the dude to just give it to me for free.
Once you get the manifold off, vacuum well because you don't want anything falling down into your engine.
When reinstalling, there is a hose that connects to the back of the manifold that is a B to get back on, as you can't see and there's not much slack on the hose to work with.
BIG TIME MUST DO - While you have the manifold off, at a minimum, remove and clean the EGR valve. I would just replace it with a new one. If you ever have to replace the EGR valve, there's no way to get to the lower bolt without removing the manifold, so if you have it off you might as well take care of that EGR. That's a lot of work to do again just to get to one bolt. (Revenue generating engineering if you ask me.)
Another note on the EGR valve - if it's suspected of being faulty, before removing the intake manifold, spray it out from the top with WD-40 and an air hose. If it sticks open or closed, it'll cause the check engine light to come on, which automatically fails most emissions inspections. Try that before spending a lot of time and/or money on a replacement job.
Again, if you've never done this job the manual is invaluable and almost a must-have.
Wiki User
∙ 15y ago
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