Well for 2 years i have had a water leak on my 2001 5.4 motor at the front right corner of the intake manifold on the aluminum water crossover tube. Had stop leak in it and kept to a small drip. Yesterday i decided to do the repairs. This involves removing the throttle body, injectors, coils, and finally the plastic intake manifold. Flip the manifold over and remove the small bolts holding the aluminum cross over on. In the photo below you can see the rubber o-ring gakset blown out inside the water port. Edge of the plastic throttle body also broke off inside. Thats what holds the o-ring. I repaired by filling in the o-ring groove and using a regular flat gasket and RTV instead of the factory o-ring seal. 3 hours to remove, 3 hours to repair, 3 hours to reinstall. Works good as of today.

<a href="http://s436.photobucket.com/albums/q...anifold013.jpg" target="_blank"><img src="http://i436.photobucket.com/albums/q...anifold013.jpg" border="0" alt="5.4 water manifold"></a>

 

how about this?

 

here is a photo of the head ports with the manifold off. the lower left side port is the passenger side front, where the crossover leaked. Leak caused a failed- shorted out coil a few months ago. Was useing about quart of water a month---after sealer installed.

 

great post!

 

Good post, sure this could come in handy to some in the future.

 

Steve, did you do anything with that small pipe that goes from the back of the water pump to the back of the engine? I heard those tend to leak as well.

 

looked at the big pipe, also the small tube with the banjo fitting. both looked good, no corrosionso i let them pass.

 

That damn gasket is what caused my engine meltdown. Instead of leaking outside, it went right down into cylinder 1 and blew the head gasket. What a bunch of crap that was.

Mike

 

What is the small tube for?

 

I beleive that small tube is from the water pump to the back of the head water jackets.....someone chime in on this if thats not right...... SteveIll....great post and pics as always!!!
Rich

 

I've the same problem on 2000 Exp 5.4. (Leak at interface of crossover and manifold.) After removing alternator, was able to remove the lower bolts on passenger side and driver side (thermostat housing). Removed two lower bolts on each. Not too difficult. In fact, the 2 upper bolts on thermostat housing were more difficult. Now trying to remove Al crossover without excessive force but seems stuck. Obviously can't use heat and I'm starting to wonder whether I might have been better off removing entire plastic manifold with crossover attached. Seems like the job would be a lot easier removing only crossover, but maybe there are good reasons to remove manifold too. Any advice would be much appreciated.

 

The tube going through the valley? That goes to the heater core. See that hose right next to the second red circle in from the left, behind the fuel rail?

 

I've the same problem on 2000 Exp 5.4. (Leak at interface of crossover and manifold.) After removing alternator, was able to remove the lower bolts on passenger side and driver side (thermostat housing). Removed two lower bolts on each. Not too difficult. In fact, the 2 upper bolts on thermostat housing were more difficult. Now trying to remove Al crossover without excessive force but seems stuck. Obviously can't use heat and I'm starting to wonder whether I might have been better off removing entire plastic manifold with crossover attached. Seems like the job would be a lot easier removing only crossover, but maybe there are good reasons to remove manifold too. Any advice would be much appreciated.

 

im not sure you can get to all the bolts without taking the manifold off. seems like i looked with a mirror and couple were not accessable. look at the cross over in the photo above... 3 small bolts on that side.

 

Thanks so much for your valuable advice and the great image. You are absolutely right- there is a totally inaccessible bolt on the intake side. Your advice has probably kept me from destroying the crossover and manifold. Looks like there's no way around it; the manifold must be removed.