I have a 1999 f-150 2wd w/4.2. On the front of the intake manifold there is a metal tube molded/pressed into intake. This tube has a hole in it and is leaking. Is there a fix for this or does entire manifold need to be replaced? I used JB weld on it and it worked for a while but then it softened and started to leak again. Any help would be appreciated. Thanks

 

this happend alot in the 1997-1999 4.2l's after about 100k the manifold would leak into the top end...i think i heard that ford had a callback on that but im not sure, but the best thing to do in this case is to replace the manifold...

 

Check out this link for your leak.
Options for repair of pinhole coolant leak - Ford F150 Forum - Community of Ford Truck Fans

 

I realize this is an old thread but I would like to update it as I just repaired a lower intake bypass pipe.

1st I first removed the old pipe and the piece left in the intake.

2nd Was to drill the hole with a 13/16" drill bit and chambered the leading edge with a 7/8" drill bit.(This was to make the lead in for the tap).

3rd Tap the hole with a 1/2" pipe tap. (I used 95% of the taps depth).

4th Assembled a 1 1/2"x1/2"NPT nipple into a 90* fitting and out of that with a 1/2"NPT x 3/4" barbed nipple.

5th Installed this assembly and the intake was fixed. (Now came the rest of the upper intake assembly).

 

I found a replacement Ford OE part.. # F75Z-8555-AB. This is the exact part to the one that continually rusts out.
First I cut off the old tubeflush. then I took a small ( and I mean small ) hacksaw and cut throught the remaining piece that is still in the manifold. I then could get the piece out. I then coated the new piece with gasket shellac and made a homemade driver out of 1/2" pipe by cutting one side off. I used it to drive the new pipe home. Works great and no leaks.