Engine Explorer - Lower intake internal cleaning

R82148V · Nov 18, 2025

OK so I got the lower intake clean even more so with the baffle off. Purchase some Red locktite and ss bolts to re-attach.

Now I have a whole other issue and can find concrete info about it.
I purchased the Felpro MS95953 Plenum gasket. Come to find out, it doesn't fit well at all!
Upper explorer intake is RF-F67E-9425-CA
Lower explorer intake is RF-F87E-9K461-BA

The bolt holes line up but the ports are way off.. Top and bottom.
Did I just buy a fluke or do i need something a little different?

BOTTOM

TOP

General karthief · Nov 18, 2025

Make the bolt holes a tic bigger and glue the gasket in place.

Noobz347 · Nov 18, 2025

Are your upper and lower matching?

I see your lower has the hole for EGR, does your upper have this too?

R82148V · Nov 18, 2025

Noobz347 said:
Are your upper and lower matching?

I see your lower has the hole for EGR, does your upper have this too?

Yeah. Both upper and lower have the EGR Port. Weird no?

rednotch · Nov 18, 2025

That's pretty much the standard any more..... Used to just by the cheap gasket set for a 96-01 explorer from parts stores that came with the graphite lower intake gaskets for under $20.. MS 95952, but they ain't cheap any more at the stores these days.

rednotch · Nov 18, 2025

R82148V said:
Yeah. Both upper and lower have the EGR Port. Weird no?

Not really early ones used the same -BA lower as the motorsports stuff, only different was the big baffle.

R82148V · Nov 18, 2025

rednotch · Nov 18, 2025

A few mins with a cut off wheel taking the corner bracket off the upper cleans them up a bit if your painting the upper. If not I would at least clear it to keep it from oxidizing.

Edit looks like you all ready sprayed it based on the core plug color though.

R82148V · Nov 18, 2025

rednotch said:
A few mins with a cut off wheel taking the corner bracket off the upper cleans them up a bit if your painting the upper. If not I would at least clear it to keep it from oxidizing.

Edit looks like you all ready sprayed it based on the core plug color though.

It actually came like this from a purchase off Ebay. Someone sprayed it already, but clearing it sounds like a good idea to keep what it is now.

Noobz347 · Nov 18, 2025

Either that or the Arctic Silver looks really nice under the hood if you're after that OEM look, too.

The problem I have with clears is that they tend to yellow.

If however, you've got your heart set on a clear, get a two-part clear. It will hold up a lot better.

Spray Max 2K Clear Coat Aerosol High Gloss Finish

Get a durable, UV-resistant high gloss finish with Spray Max 2K® clear coat. Easy spray application, quick dry, and long-lasting protection.

steelfxpatinas.com

AeroCoupe · Nov 18, 2025

I am not saying the Felpro gasket is the problem but you may want to try the Ford Performance one to verify.

EFI GT-40 UPPER-TO-LOWER INTAKE MANIFOLD GASKET

EFI GT-40 UPPER-TO-LOWER INTAKE MANIFOLD GASKET|Ford Racing Parts

performanceparts.ford.com

I had a Cobra upper and lower and don't remember an issue with the Ford Performance gaskets. I will say that just trimming the Felpro one is probably easier and it doesn't hurt them one bit.

Mustang5L5 · Nov 19, 2025

I think i have a felpro cobra gasket on my shelf and my RF-F67E-9425-CA explorer upper on my bench. Let me see how that fit is.

My lower was ported, so the fit was different.

I bet this is just poor quality fit due to manufacturing slop.

Mustang5L5 · Nov 19, 2025

ports to the front line up ok. Rear ports definitely off a tad. Still within the circles of the gasket though

R82148V · Nov 19, 2025

Mustang5L5 said:
ports to the front line up ok. Rear ports definitely off a tad. Still within the circles of the gasket though

Thats how mine looks. Its almost like the gasket is just a little too long.

R82148V · Dec 5, 2025

ok. sorry for the long delay on an update, but i was able to take out the rivets, scrape, soak with degreaser, used brass bottled brushes for the runners and it all came out way better than expected. picked up a gasket from Mahle and it was a perfect match. steel core too. Just about ready to prep it for a touchup coat of of cast coat aluminum engine paint from Duplicolor.

So my next issue is how the heck do you clean out the upper? its soo crazy caked with oil carbon stuff that you can scrape it easily with a screwdriver but you can only get to far. how do you get all of it out, the unreachable places?

R82148V · Dec 5, 2025

rednotch · Dec 5, 2025

Again.. Dollar store oven cleaner in the ports and pressure washer.. Not all but some Dollar generals have home bright heavy duty oven cleaner for a buck a can, you can usually find if the store has it or not on there little app....

Cheapest diy degreaser option these days. Just cleaned up a core trans and transfer case that we picked up for my brothers truck that way, soak in oven cleaner then pressure wash, repeat until its just stained aluminum. If you want to go further, aluminum brightener will remove stains. Only way your getting it cleaner is vapor or glass beading.

R82148V · Dec 5, 2025

rednotch said:
Again.. Dollar store oven cleaner in the ports and pressure washer.. Not all but some Dollar generals have home bright heavy duty oven cleaner for a buck a can, you can usually find if the store has it or not on there little app....

Cheapest diy degreaser option these days. Just cleaned up a core trans and transfer case that we picked up for my brothers truck that way, soak in oven cleaner then pressure wash, repeat until its just stained aluminum. If you want to go further, aluminum brightener will remove stains. Only way your getting it cleaner is vapor or glass beading.

oven cleaner and power washer it is. how long should the soak be?

rednotch · Dec 5, 2025

Its foam, if its caked bad wait for the foam to break down and you want to wear gloves and try not to breath it when spraying it, really have to let it build up in the ports or it will just run down one side. A hot water soak will help some after but hard to do in winter.

I had to clean one out mice nested in from sitting off a car, used a bore scope to check it it was packed. getting the mouse nest, and bird seed out that they packed it with was a pita since you need to fully flood it to flush every corner of it.. a $10 dollar kids pool comes in handy for stuff like that so you can submerge larger stuff, but summer time work

AeroCoupe · Dec 5, 2025

5 gallon bucket purple power. It will cause the aluminum to turn a flat gray color but if you’re going to paint it then it’s a moot point. I soaked a caked bell housing in a tote for a couple weeks and it took care of business.

Engine Explorer - Lower intake internal cleaning

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wonder how much it would cost to ship you a pair

Stangnet Facilities Maint Tech... Er... Janitor

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I'd like to remain having one chocolate starfish

I'd like to remain having one chocolate starfish

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I'd like to remain having one chocolate starfish

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Stangnet Facilities Maint Tech... Er... Janitor

lube between the nut and the face. I know my lubes

That is…until I whipped out my Bissell

That is…until I whipped out my Bissell

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I'd like to remain having one chocolate starfish

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I'd like to remain having one chocolate starfish

lube between the nut and the face. I know my lubes

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