4.6L (1996-2004 Modular) Mustang Technical discussions on 1996-2004 4.6 Liter Modular Motors (2V and 4V) within.

Thermostat housing leak

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Old 10-14-2017, 09:45 PM
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Larry2004Mustang
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Default Thermostat housing leak

2004 Mustang GT 4.6L

Is that part all 1 piece? Do I need a new intake manifold? I found it leaking between the cast and the plastic portion at the thermostat. Looks like the whole engine comes apart for this. I pray I'm mistaken.
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Old 10-15-2017, 11:08 AM
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dawson1112
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yea its all one piece you have to replace the intake manifold, its common problem with them, But it really isnt all that hard to do.
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Old 10-15-2017, 11:22 AM
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Larry2004Mustang
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OK, Thank You very much! Maybe there is an all metal intake manifold available so let the shopping begin.

Only 70K miles on the vehicle so probably will occur again if I use the same plastic crap. UGH!
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Old 10-15-2017, 01:19 PM
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Z28KLR
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Just replace it with another oem Ford piece. There are aftermarket aluminum manifolds out there, but the few that aren't too expensive may require a couple other things to make them work (different throttle body elbow, fuel rails etc) and at any rate they really aren't the best choice as far as performance for a stock or mostly stock engine. And whatever you do, don't buy the Dorman brand replacement. Feel free to Google why on that.

Where yours cracked is actually kinda rare. Does happen, but I wouldn't be too afraid of the next one doing the same thing. Replacement is actually pretty easy, looks worse than it is. I've done 'em at least 3 times, once on my car and twice on others. First time took about 3 hrs, I can do it in about half of that now lol. Get a Haynes manual for your car, it outlines the step by step and torque values.
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Old 10-17-2017, 06:57 AM
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WhiteFoxGT
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Originally Posted by Larry2004Mustang
OK, Thank You very much! Maybe there is an all metal intake manifold available so let the shopping begin.

Only 70K miles on the vehicle so probably will occur again if I use the same plastic crap. UGH!
like stated above this post, stick with a ford plastic one. Ive seen many people make the mistake of getting the edelbrock intake and they have no idea the can of worms they just opened to get it to fit just to lose power
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Old 10-17-2017, 01:18 PM
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Derf00
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Age and condition of the environment are what break down plastics, not number of miles driven. Just replace it with the OEM and forget about it.
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