puked all my coolant

2006KJ · Jun 3, 2010

well.. it happened. the nipple on the back of the intake manifold that goes to the heater core broke today... and then pumped out all my coolant everywhere including the windshield, fenders, hood, and a small lake on the road for 30 feet or so. so today i ordered...

- PI intake manifold from american muscle
- Upper and Lower intake gaskets (do i need both or just lower?)
- 0-rings for the fuel injectors (8)
- Will order a new water pump soon as i get it off to see the width (2 available.. one is 60some mm from the pully end to block the other is 87mm)
- Water pump nipple
- Heater hose that goes in the valley of the block from the water pump back

my car is an early built car in 2001 (i have the T45 tranny).. do i need anything else (besides coolant)? Also any tricks to installing this? i keep seeing something about the altinater bracket? any advice is appreciated!

Shiroelex · Jun 3, 2010

You shouldn't have to worry about the alternator bracket. That's if you are swapping from NPI to PI. Also, there technically isn't an upper intake gasket. Most intakes have an integrated rubber seal where the plenum mounts. I believe the Dorman intake uses that same gasket style on the lower mounts as well.

RedDaemon · Jun 4, 2010

2006KJ said:
well.. it happened. the nipple on the back of the intake manifold that goes to the heater core broke today... and then pumped out all my coolant everywhere including the windshield, fenders, hood, and a small lake on the road for 30 feet or so. so today i ordered...

- PI intake manifold from american muscle
- Upper and Lower intake gaskets (do i need both or just lower?)
- 0-rings for the fuel injectors (8)
- Will order a new water pump soon as i get it off to see the width (2 available.. one is 60some mm from the pully end to block the other is 87mm)
- Water pump nipple
- Heater hose that goes in the valley of the block from the water pump back

my car is an early built car in 2001 (i have the T45 tranny).. do i need anything else (besides coolant)? Also any tricks to installing this? i keep seeing something about the altinater bracket? any advice is appreciated!

i dont think i have ever read a case of this manifold breaking in this spot before. were you working in that area prior to the break?

Read this:
99-01 PI to PI Intake Manifold Swap Writeup - Mustang Forums at StangNet

kuwait · Jun 4, 2010

RedDaemon said:
i dont think i have ever read a case of this manifold breaking in this spot before. were you working in that area prior to the break?

Read this:
99-01 PI to PI Intake Manifold Swap Writeup - Mustang Forums at StangNet

its quiet common , i seen it 3-4 times at least , also i haven't seen a car that didn't break its plastic intake eventually , mine is a 2004 and mine broke at the thermostat housing and yes it had alum cross overs , maybe its the hot weather here but those plastic intakes are just asking for trouble.

RedDaemon · Jun 4, 2010

kuwait said:
its quiet common , i seen it 3-4 times at least , also i haven't seen a car that didn't break its plastic intake eventually , mine is a 2004 and mine broke at the thermostat housing and yes it had alum cross overs , maybe its the hot weather here but those plastic intakes are just asking for trouble.

thats so disheartening.

patman0911 · Jun 4, 2010

You don't need the nipple or valley hose - That's only of you're replacing an NPI intake with a PI.

You probably will need the alternator bracket. The bracket mounting locations for plastic crossovers and aluminum crossovers are different. You may be able to modify yours but I'm not positive about that - the plastic crossover PI intake has much different mounting locations than either of the NPI intakes or the aluminum crossover PI intake.

If you're getting gaskets, you might as well get the lowers and the upper too.

RedDaemon · Jun 4, 2010

patman0911 said:
You may be able to modify yours but I'm not positive about that

for his particular situation, he can modify the alternator bracket he already has, theres a pic of it in that writeup i linked to above

patman0911 · Jun 4, 2010

RedDaemon said:
for his particular situation, he can modify the alternator bracket he already has, theres a pic of it in that writeup i linked to above

Ah, yep, looks like modifying the old bracket will be fine.

Excellent writeup, BTW - love the color highlighted photos and arrows pointing stuff out

2006KJ · Jun 4, 2010

RedDaemon said:
for his particular situation, he can modify the alternator bracket he already has, theres a pic of it in that writeup i linked to above

yes EXTREMELY good write up... i dont think it could possibly be any better. and thanks for all the other input too... i already ordered the valley pipe so i might as well keep it... with 109000 miles mine could probably used replaced anyway. anymore advice is appreciated! this site has great people and a wealth of knowledge for sure!

jlds91389 · Jun 6, 2010

mine broke in the same place lol. i have the dorman intake it didnt require any gaskets. mine also cam with three brakets to choose from. i had to use a diffrent one than stock.

RedDaemon · Jun 7, 2010

patman0911 said:
Ah, yep, looks like modifying the old bracket will be fine.

Excellent writeup, BTW - love the color highlighted photos and arrows pointing stuff out

2006KJ said:
yes EXTREMELY good write up... i dont think it could possibly be any better. and thanks for all the other input too... i already ordered the valley pipe so i might as well keep it... with 109000 miles mine could probably used replaced anyway. anymore advice is appreciated! this site has great people and a wealth of knowledge for sure!

thank you both and good luck with the install

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