GT Tommy

Don't recall what sealant I used on the pipe thread. Just don't use any sealant that has silicone in it, the silicone will damage your 02 sensors. It took me around 4 hours from start to finish to replace the intake. I took my time, trying to do everthing correctly. I also found several vacuum hoses cracked or broken, which I replaced. When you remove your hoses, inspect them with a fine tooth comb. After you remove each hose, bend them to see if any crackes show up. It's better to find them now, while they are removed. I'm sure the job can be done in around 2 hours if you are in a hurry. What is also very important is making sure you follow the torque sequence and use the correct torque value for what ever intake you use. What intake are you going to use? By the way, we replaced the thermostat with one that has a 180 setting. So far, no overheating problems. To me, the stock thermostat is designed for trouble. That's just my personal opinion! Good luck, Tommy.

MUST9819

1 more question, this new dorman intake, there are 2 brackets that came with it i would assume that are for the alt, but there is no way they will work. i know yours was a 93 and mine is a 98. but i was wondering if the old bracket will work. as you can see i am taking my time with doing this. guess i will call dorman and ask them too.

GT Tommy

If you were referring to me, my son has a 2003 GT Mustang. We did purchase the Dorman brand PI intake. I was able to use one of the new alternator brackets with the stock alternator. However, just yesterday I replaced the alternator with one that has a 160 amp rating. For this new alternator, I found that the stock alternator bracket had a better fit. The bracket that I had on previously that came with the Dorman intake extended further back towards the firewall direction covering the vacuum hoses. I noticed that when I removed that bracket yesterday, the design of that bracket actually crushed one of the vacuum hoses. I would say if the original bracket works for you, everything lines up properly, and the bracket does not come in contact with anything that it should not touch, go for it. Not a problem. Good luck, Tommy.

gunpig0313

Pressure test it, it will tell you were the coolant is leaking from.

Dilley

i tried pressure testing it but the tester i could gt would not seal on the filler neck of the rad

MUST9819

well i got it all together this afternoon, took my time on it started Saturday when it was about 95 and did that suck but it cooled off this week so went pretty smoothly. the only problem i see is the after market brkts for the alt they just screw up all the hosing for the IAC. but other than that all good thanks for your help GT Tommy

stangdriver2007

the 1996 should not have a filler neck. they should be a screw on style. it probably is cracked by the sensor. i have a dorman aluminum replacement. ive had it for 3 years and no problems

gunpig0313

The testers should have an adapter for the Ford vehicles.

GT Tommy

Have you figured out which alternator bracket fits best? Tommy.

MUST9819

yea i don't know how to describe the way it looks, it has the two holes on the front of the brkt on each side. i will probably cut the backside of it off and smooth it down seeing how it has no function.