PI Performance Improved Intake Manifold for 4.6L Mustang

[Ducati998ss]

Hey all i need some help. I own a 98 Gt with 92K miles on it. Last weekend my intake manifold cracked and leaked coolant everywhere. Well i took into ford and they first told me it was covered under that warranty thing. Then the next day they told me it wasnt and that i was past the 7 years (which sucks since i have only owned this car for like 2 years and that bill got passed like what last year or earlier). Anyways the dealership wants a $1000 to fix it. Im a college student and dont work full time. Besides i hate dealers touching my car. Anways a friend told me about the PI Intake manifold and how with some modifications it can fit onto a 98. Does anyone know of or have a link to a site or anything that shows the modifications that need to be done to fit the 98? Also has anyone done this before on a 96-98 already before? Just to let you guys know i may to the PI heads eventually, but right now i just need the easiest and least expensive fix. Its my daily driver and as of right now i dont have a car. Im not looking for performance, but i also dont want to put another 98 OEM intake manifold on.

Description:
Current production plastic intake manifold used on 2001-03 4.6L SOHC 2V Mustang GT. Less expensive alternative to aftermarket performance intake manifolds for PI head swaps. Manifold fits 1999-03 Power Improvement head ports. Great for custom engine builds. Can be used on 1996-98 engines with additional modifications and parts sold separately. (Gaskets and wiring harness not included).

And what it looks like:

 

[tjm73]

I think the extended warrenty is 7 years on top of the 3 years the cars came with from the factory. So that's 10 years from production. I'd go straight to Ford and inquire first. Also check the thread that's stickied. I think the dealer may be mistaken.

Edit: I did some checking it's 7 years from the warrenty start date.

Do a search on the PI intake on NPI heads. Been covered here at least 2 or 3 times.

Sean Hyland Motorsports (and others) have what they call "Problem Solver" intakes specifically for the NPI head engines. It has the aluminum cross over like the good intakes have. It's $270 bucks,

http://www.seanhylandmotorsport.com/online/product_info.php?cPath=30&products_id=1057

 

[Mike97gt]

dont pay 1000 bucks to do this. the dealer wants almost 500 for the part alone. and then probally 5-6 hours labor. the recall pays 3.0 and most dealers including mine double the warrenty time when quoting cash work.

if you live in eastern ma i will do yours for a lot less.

 

[Ducati998ss]

I think the extended warrenty is 7 years on top of the 3 years the cars came with from the factory. So that's 10 years from production. I'd go straight to Ford and inquire first. Also check the thread that's stickied. I think the dealer may be mistaken.

Edit: I did some checking it's 7 years from the warrenty start date.

Do a search on the PI intake on NPI heads. Been covered here at least 2 or 3 times.

Sean Hyland Motorsports (and others) have what they call "Problem Solver" intakes specifically for the NPI head engines. It has the aluminum cross over like the good intakes have. It's $270 bucks,

http://www.seanhylandmotorsport.com/online/product_info.php?cPath=30&products_id=1057

okay now whats the difference between that and what i posted? is that one already modified for my engine so i dont need to do any more modifications? Or do i still need to do some type of modifications? Also will that one attach to the stock heads fine or do i need to by new heads as well?

 

[Ducati998ss]

Do a search on the PI intake on NPI heads. Been covered here at least 2 or 3 times.

Sean Hyland Motorsports (and others) have what they call "Problem Solver" intakes specifically for the NPI head engines. It has the aluminum cross over like the good intakes have. It's $270 bucks,

http://www.seanhylandmotorsport.com/online/product_info.php?cPath=30&products_id=1057

okay now whats the difference between that and what i posted? is that one already modified for my engine so i dont need to do any more modifications? Or do i still need to do some type of modifications? Also will that one attach to the stock heads fine or do i need to by new heads as well?

 

[kuma]

Randy Stinchcomb sells a kit for the PI intake upgrade for around $300. Basically all you need is a PI intake, PI gaskets, silicon sealent, new cross-over tube. Visit modulardepot.com and do a search. There are many people that have done the swap.

 

[tjm73]

okay now whats the difference between that and what i posted? is that one already modified for my engine so i dont need to do any more modifications? Or do i still need to do some type of modifications? Also will that one attach to the stock heads fine or do i need to by new heads as well?

The "Problem Solver" intake is a Non-PI intake (ie: works withthe OEM heads on a 96-98 Mustang) with the aluminum coolant crossover instead of the plastic coolant crossover like stock. That's what fails and this Non-PI intake fixes the problem. It's a stock type replacement so it's a remove and replace intake. No special requirements.

 

[TGJ]

You can get the PI intake and required parts for under $230.00, if you know where to get the parts. I have done the swap. You need a plastic PI intake with the aluminum crossover, PI coolant tube that runs in the valley of the heads, PI o-ring for the water pump, PI intake gaskets, RTV sealant and possibly the alternator bracket for the aluminum crossover.

Using these parts that I listed you will need to:

1) Modify the PI gasket, remove nipples that go into the PI head to line up the gasket, NPI heads do not have these holes.

2) Accomodate the 2nd heat sensor in the NPI crossover, PI intake only has one. I suggest you drill and tap the PI intake as there is a spot on the aluminum crossover for this. I don't recall the size of drill and tap required.