2002 Expedition Eddie Bauer 5.4 intake replacement

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Rick C

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Jan 11, 2025
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Looking for advice in replacing the intake manifold on my 2002 Expedition 5.4. I had it done a few years ago with an aftermarket (Dorman) intake, and it has begun to leak coolant into the rear cylinders again, and is fouling out my plugs & coil packs (cyl. 1 & 2). I’d like to do this myself, and I’m pretty handy with this kind of work. Just unfamiliar with the level of difficulty, and would like advice as to whether I should tackle it or just let a garage do the job again. Thanks for the advice, in advance.
 

Jamesjmr

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Aug 4, 2024
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I just replaced my intake a couple of months ago along with the (water) pump because it was easily accessed, the level of difficulty is determined by your skill level. My skill level is hard fought, the gates to enlightenment are guarded by the sentries of paradox and confusion, Working in my unheated garage in Jan during a polar vortex . All in it took me about 7 +- hrs. In retrospect make sure you take videos as you dissemble, the video reference will be the key to overcome anomalies that you may face. the quality of the dorman intake quality was nowhere near the factory intake however the factory intake has been discontinued. shortly after that repair in February my fuse box melted on the coldest and snowy day due to a faulty fuel pump relay I replaced the fuse box with a dorman box. The next day No Crank No Start battery voltage 3v. I swapped batteries it fired up runs fine except it's throwing DTC'S U1262, B2900, C1805 AND B2900 and there is a parasitic draw that drains the battery over night, Using my Power Probe Maestro helped me diagnose the draw to the rear wiper motor. I never had a problem with the operation of the wiper motor until the electrical issue occurred. it's always something and it makes life interesting .
2003 Expedition 152k MI
 
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