Yet another round with the 4.6 composite intake maniford

My second manifold (first one replaced via warranty) is not as bad as the first one but its bad. I have patched leaks with JB quik weld in several places where water just started oozing out. It's never held a
steady water level since I've owned it (new in 97).
Looks like replacement time. Any advice out there? Alum? How much? Another plastic? How difficult a job is it for a weekend mechanic?
TIA, Frank
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all the replacement manifolds have been alunimum water crossover for a few years now. that solved the problem with cracking.
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Tom wrote:

I just found that item for 269.00. http://www.1aauto.com/1A/Drivetrain/Ford/Thunderbird/1AEIM00010/136110
Guess its OK. Any feedback about difficultly? Especially interested in tricks or pitfalls.
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F. H. wrote:

Removal:
Disconnect battery ground cable.
Drain engine cooling system.
Relieve fuel system pressure and disconnect fuel lines.
Remove air cleaner outlet tube.
Release drive belt tensioner and remove drive belt.
Disconnect all ignition wires from spark plugs. Do not pull on ignition wire as wire may separate from the connector in the ignition wire boot.
Disconnect ignition wires and ignition wire separators from valve cover stud bolts.
Disconnect fuel charging wiring from both ignition coils and camshaft position sensor (CMP sensor).
Remove four bolts retaining ignition coil to ignition coil brackets.
Disconnect alternator wiring harness from junction block at front fender apron and from alternator.
Remove four bolts retaining alternator mounting bracket to intake manifold.
Remove bolts retaining alternator to cylinder blocks and remove alternator.
Raise vehicle on a hoist.
Disconnect fuel charging wiring from the oil pressure sensor and electronic variable orifice sensor and position fuel charging wiring out of the way.
Disconnect EGR valve to exhaust manifold tube from RH exhaust manifold.
Lower vehicle.
Disconnect accelerator cable and speed control actuator cable from throttle body.
Remove accelerator cable bracket from intake manifold and position out of the way.
Disconnect vacuum hose from throttle body adapter vacuum port.
Disconnect heater water hose.
Note: Two water outlet connection retaining bolts also retain intake manifold.
    Remove two bolts retaining water hose connection to intake manifold and position upper radiator hose and water hose connection out of the way. (Note: Two water outlet connection retaining bolts also retain intake manifold)
Remove the remaining nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
Remove intake manifold gaskets.
Installation:
If a new intake manifold is being installed, transfer all necessary components onto new intake manifold.
Clean sealing surfaces of intake manifold and cylinder heads.
Position new intake manifold gaskets on cylinder heads.
Position intake manifold on cylinder heads. Make sure alignment tabs on intake manifold gasket are aligned with holes in cylinder heads.
Install and tighten intake manifold retaining bolts one through nine in sequence to 20-30 N-m (15-22 lb-ft).
Replace O-ring seal on water hose connection. Position water hose connection and upper radiator hose and install two bolts and tighten to 20-30 N-m (15-22 lb-ft).
Connect heater water hose.
Connect vacuum hose to throttle body adapter vacuum port.
Install accelerator cable bracket on intake manifold and connect accelerator cable and speed control actuator cables to throttle body.
Raise vehicle.
Connect EGR valve to exhaust manifold tube to RH exhaust manifold and tighten nut to 35-45 N-m (26-33 lb-ft).
Connect the fuel charging wiring to the electronic variable orifice sensor and oil pressure sensor.
Lower vehicle.
Position alternator and install two retaining bolts. Tighten to 20-30 N-m (15-22 lb-ft).
Install two bolts retaining alternator rear mounting bracket to intake manifold and tighten to 8-12 N-m (71-106 lb-in).
Connect alternator wiring harness to alternator, RH front fender apron and junction block.
Position ignition wires and ignition wire separators on engine and install bolts retaining ignition coil to ignition coil brackets. Tighten bolts to 8-12 N-m (71-106 lb-in).
Connect all ignition wires to spark plugs.
Connect ignition wire separators on valve cover studs.
Connect the fuel charging wiring to both ignition coils and camshaft position sensor.
Install drive belt.
Install air cleaner outlet tube.
Connect fuel lines.
Connect battery ground cable.
Fill and bleed engine cooling system.
Check and fill crankcase to specified level with engine oil.
Start engine and check for leaks.
Piece of cake!
Rob
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trainfan1 wrote:

snip instructions for space / / / / /

LOL, thanks. Wish me luck, God hates a coward.
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F. H. wrote:

I've done a alot of intakes on the CVs. Not sure about a Tbird but I never had to raise the car, and never took the fuel lines off, just moved the rails over out of the way....A by the way, piece of cake-good luck...:)
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ShoeSalesman wrote:

Thanks. Added to Rob's instructions and saved.
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F. H. wrote:

Do a Google search for: Northern Auto Parts I don't have the part number handy, but if you do a search for "intake manifold", you will find the same thing for $200.
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Kruse wrote:

Thanks much. You are correct:
http://www.northernautoparts.com/ProductModelDetail.cfm?ProductModelId 498
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