Broke my PI intake manifold.....again - TCCoA Forums
 
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post #1 of 12 (permalink) Old 04-21-2014, 06:11 PM Thread Starter
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Broke my PI intake manifold.....again

About a month ago I finished up my PI swap on my new-to-me Bird. The previous owner had seized the camshafts and thus the engine was no good. He had done at some time in that cars life a PI engine swap. So on this new engine I reused the PI intake manifold. Well Saturday I was coming home from work in the mid morning hours. I gave the car a WOT punch from a stop and when it shifted into second it shot coolant all over the windshield. As soon as it happened I knew what it was because my old 95 did it after I did the PI intake swap on that car using a used PI intake. Both cars broke the water jacket off of the intake where the heater core hooks up.

I was pretty PO'd but I ordered a new manifold from Summit as soon as I got home. And it arrived today when I got home from work. Super quick shipping especially over Easter weekend. I'll post pictures when I get the chance either tomorrow or late tonight. Already had my friend drill and tap the new crossover for the ect so now I just need to get it hooked up.

Have any of you guys had this problem before? This is my second time and a vow to never buy a used plastic PI intake again.

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post #2 of 12 (permalink) Old 04-21-2014, 06:13 PM
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I've blown the coolant hose a couple of times but I haven't busted a manifold yet. Well, let me rephrase that, I blew the hose once, cut the hole out, put the hose back on and blew it again. These kinds of things happen when your a cheap bastard.

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post #3 of 12 (permalink) Old 04-21-2014, 06:21 PM
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I have a hairline crack in mine, but I have the PI sitting in a box ready to go. No WOT punches for me, hence why it's still holding strong. I know it's under pressure, but my car never gets hot enough to cause a major issue (yet.)
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post #4 of 12 (permalink) Old 04-21-2014, 06:41 PM
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The alternator twists the crossover; high rpm shifts are what does it, lol.
That's how I broke the stock pos plastic manifold in Lazarus.

My metal crossover PI hasn't had this problem yet.

The fix is an overrunning clutch in the pulley on the alternator like the newer cars have.

EDIT: I'm A DA; I missed this "water jacket off of the intake where the heater core hooks up." Ain't done that yet.

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Last edited by Grog6; 04-21-2014 at 06:59 PM.
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post #5 of 12 (permalink) Old 04-21-2014, 06:42 PM
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Never heard of this, where it breaks at the heater core nipple. It must have been defective from the start because there are millions of PI intakes out there that this has not happened to.
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post #6 of 12 (permalink) Old 04-21-2014, 07:18 PM Thread Starter
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Quote:
Originally Posted by guitar maestro View Post
Never heard of this, where it breaks at the heater core nipple. It must have been defective from the start because there are millions of PI intakes out there that this has not happened to.
Possible but I had it happen twice to me with 2 different used manifolds.

Daily Driver - 2014 Ford Mustang GT 5.0 manual black on black. Stock for now.

Current Project - 1996 T-bird LX 4.6L: PI head swap, factory 3.27 TL, tuned by Don LaSota.

Retired Car - 1995 T-bird LX 4.6L: 4v swap plus Cobra goodies
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post #7 of 12 (permalink) Old 04-21-2014, 08:07 PM
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I've had a customer come in to my store with this same problem. 99 or so Mustang Gt. Nipple broke right the h*** off.

Michael M. ASE P2 Automobile Parts Specialist.

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post #8 of 12 (permalink) Old 04-21-2014, 09:36 PM
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I have seen several break the nipple off the intake. For some reason, the intakes with the plastic crossover had a brass nipple at the back, but when they went to the aluminum crossover, the nipple became made out of plastic, and just like the plastic crossover, eventually it becomes brittle and cracks.

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post #9 of 12 (permalink) Old 04-21-2014, 11:17 PM
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The pressed in brass nipple isn't much better than the molded in plastic. I have had two nPI intakes fail at that point, hairline crack in the plastic and press fit is no longer press fit. I am pretty careful and don't twist it or beat it around, but I do pop the hose off when I fill an empty cooling system so it might get more hoses on and off than normal.

My 97 Cougar used to shoot off the heater hose, I have a video of it when revving up the engine the heater hose would defect almost 2 inches to the side. After I did the PI swap and monkeyed around with the other hose (I used the Mustang under intake tube that ends on the drivers side of the engine, not the passenger side) I didn't have than happen anymore.

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post #10 of 12 (permalink) Old 04-22-2014, 12:45 AM
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I've had a PI intake fail at that location as well.

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post #11 of 12 (permalink) Old 04-22-2014, 09:01 AM
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on the mustang gt my brother has his did the same.

it looked like it was heat or flaw but the new one he put on is fine.

the new one he put on looks like it has heat fins on the bottom of the nipple that looks like strength and heat protection for it.
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post #12 of 12 (permalink) Old 04-23-2014, 02:35 PM
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Maybe those "fins" are webbing to keep the nipple from flexing and developing a crack. I always though the integral plastic nipple was superior since the boss that held the brass nipple in the past always seemed to crack on npi intakes, guess that is not the case. Luckily I'm rocking the 05 mountaineer intake drilled and tapped with pipe nipple on the right rear corner.

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