Accufab plenum problems!!! need help

[stang976]

ok so i finally got motivated to install my: accufab TB/plenum combo and my blower when i came across 2 horrible problems:
1) when i removed the stock plenum i did not see the original gasket (could it have dropped in to the manifold?)
2) when bolting the factory (i think its the EGR??) to the plenum with Accufabs supplied gaskets and original ford screws: the piece would not go tight against the new plenum (i was thinkin the screws were too long) so when i tried to turn the bolt (8mm) in a little farther, the head of the bolt snapped and i was left with the headless screw stuck inside the plenum. My friend is drilling the bolt out for me, but i was wondering on WTF to do on my second attempt. PLEASE HELP!!!!

 

[NasaGT]

Use the Accufab supplied screws! Thats what I used, no problems.

Also, you may want to try to use vice-grips to remove that screw rather than drilling it out.

 

[sacstoy02gt]

You're probably going to have to shim the bolt on the egr with some washers. It's not pretty, but it will work.
The plenum should have no gasket where it meets the manifold, there should be an o-ring though(blue/green in color). See pic of mine removed(o-ring is the blue/green oval):

 

[stang976]

Use the Accufab supplied screws! Thats what I used, no problems.

ahhh hah. accufab did not provide screws in my kit. that solves that problem. any thoughts on the magically disappearing gasket?

 

[Rocketman]

The Plenum to manifold gasket is a built in rubber gasket, no need to change or remove. As far as the EGR bolts are concerned, I used the original Ford bolts and the Accufab supplied gasket with no problems.

 

[stang976]

You're probably going to have to shim the bolt on the egr with some washers. It's not pretty, but it will work.
The plenum should have no gasket where it meets the manifold, there should be an o-ring though(blue/green in color). See pic of mine removed(o-ring is the blue/green oval):

thanks for the info! im gonna call accufab and see if i can get the screws that were missing in my kit. no plenum gasket huh? thats what i wanted to hear. thanks again for the info!

 

[stang976]

As far as the EGR bolts are concerned, I used the original Ford bolts and the Accufab supplied gasket with no problems.

see that i find hard to believe. when i put the original bolts up to the EGR/plenum they looked a little too long to begin with. When i started tightening the bolts, they felt really tight but i still had a lot more to go to hold the EGR in place. i should have used washers i guess.

 

[onesticker]

Let me know how much additional power you get from that when you are done. I am curious to see how it reacts with the blower.

 

[stang976]

Let me know how much additional power you get from that when you are done. I am curious to see how it reacts with the blower.

absolutley. i will post dyno sheets as soon as i get the blower in and have it tuned.

 

[mnrlgray02]

I actually had to hand tap the holes a little deeper to get the bolts to fit. Kinda PITA but it worked and then fit flush.

 

[stang976]

I actually had to hand tap the holes a little deeper to get the bolts to fit. Kinda PITA but it worked and then fit flush.

do you think i could just cut the bolts a little shorter????

 

[mnrlgray02]

I can't see why not... Just everytime I try to cut anything I f*@$ it up

 

[stang976]

update: spent hours at my buddies house on the drill press with this POS trying to get the bolt out. after about 2 hours (breaks included) we hollowed it out, heated it up real good, and tried extracting it but with no luck. eventually we just tapped it down but to a smaller bolt size. now i must go to the hardware store and pick up the correct bolts for this mystery hole.

 

[Premium Speed]

that sucks...mine bolted right up with no problems and i used the factory bolts. mine came with new IAC bolts, not EGR.

 

[onesticker]

update: spent hours at my buddies house on the drill press with this POS trying to get the bolt out. after about 2 hours (breaks included) we hollowed it out, heated it up real good, and tried extracting it but with no luck. eventually we just tapped it down but to a smaller bolt size. now i must go to the hardware store and pick up the correct bolts for this mystery hole.

This is not very encouraging. I want to do this mod but not with the headaches you're having. I wonder if the C&L or Trickflow would be any easier to install?

 

[stang976]

This is not very encouraging. I want to do this mod but not with the headaches you're having. I wonder if the C&L or Trickflow would be any easier to install?

i really just think i got the ugly duckling of the batch. my friend has the accufab combo and we had that in in no time, but mine was a defect i believe. advice: if the bolt feels really tight but the piece (EGR ?? ) is not secure on the plenum........USE WASHERS; DONT FORCE IT

 

[Premium Speed]

This is not very encouraging. I want to do this mod but not with the headaches you're having. I wonder if the C&L or Trickflow would be any easier to install?

accually the accufab "should" come with everything you need to install it...this thread sounds like an "installer error" more than a problem with the plenum, but i could be wrong...i have installed 3 of these with no problems whatsoever

 

[stang976]

accually the accufab "should" come with everything you need to install it...

well my kit never came with any bolts or screws, just 2 gaskets and accufab stickers. hence i used ford factory bolts which i heard is a :nononono: did the ones you installed have supplied bolts?

 

[Premium Speed]

well my kit never came with any bolts or screws, just 2 gaskets and accufab stickers. hence i used ford factory bolts which i heard is a :nononono: did the ones you installed have supplied bolts?

i used the factory EGR bolts on all 3 cars if i remember correctly...all 3 kits came with gaskets and IAC bolts, no EGR bolts

 

[stang976]

i used the factory EGR bolts on all 3 cars if i remember correctly...all 3 kits came with gaskets and IAC bolts, no EGR bolts

well to be honest im not sure if it was the IAC or the EGR. its NOT the one that looks like a little flying saucer. its the other little housing piece. in any case no bolts were supplied in my kit, therefore i used the factory ford bolts which i realized now were too long, hence they broke off in the plenum when tightened. anyways a little ghetto machine work and i am back to stage 1.