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Old 05-27-2013, 05:51 PM   #1
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Intake manifold

I have a 1996 and was wondering how hard it is to do the job yourself? I have some knowledge but not sure if what I have is enough to do it. It has a crack in it so I am leaking coolant and just need it replaced ASAP.
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Old 05-27-2013, 06:03 PM   #2
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Its pretty easy, upgrade to a PI intake with the metal coolant crossover, I actually have one for sale if interested. Google "PI intake swap" for more info on it but its a 1-2 hour job if you are good at wrenching on your car and the PI intake is MUCH better than the NPI or the Dorman.
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Old 05-27-2013, 06:42 PM   #3
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So I would only need the new pi intake and what else to put it on? I was told I would need the pi heads to put that intake on.
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Old 05-27-2013, 06:52 PM   #4
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Nope, the PI intake is a direct bolt on. I forget if you use the NPI or PI gaskets... either way its as easy as just swapping intakes. Google the swap and get more info on it. The one I have for sale has the metal crossover and won't leak like the 99/00 units. Like I said, if interested let me know.
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Old 05-27-2013, 07:03 PM   #5
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Quote:
Originally Posted by Sn96 View Post
I have a 1996 and was wondering how hard it is to do the job yourself? I have some knowledge but not sure if what I have is enough to do it. It has a crack in it so I am leaking coolant and just need it replaced ASAP.
You have to replace some other stuff too

It isn't a direct swap
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Old 05-27-2013, 07:23 PM   #6
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Click me

Its about as direct a swap as you can get with going from one year to another etc...
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Old 05-27-2013, 07:25 PM   #7
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DO NOT buy a Dorman, only buy a Ford Racing
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Old 05-27-2013, 07:27 PM   #8
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Quote:
Originally Posted by BigB227 View Post
DO NOT buy a Dorman, only buy a Ford Racing
+1 dorman WILL crack
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Old 05-27-2013, 07:32 PM   #9
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Also the Dorman is NPI, not PI no matter what they say. It flows like ****, has terrible casting flash etc... easy to tell which is which.
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Old 05-27-2013, 07:37 PM   #10
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What else would I need for the swap then? And dm me about that intake I'm interested.
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Old 05-27-2013, 07:40 PM   #11
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I posted you a link with an entire parts break down and how to, click it. PM is going out.
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Old 05-27-2013, 08:48 PM   #12
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Thanks man.
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Old 05-27-2013, 09:50 PM   #13
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Pi intake on npi heads, pretty simple. Buy a pi intake manifold, pi intake manifold gaskets, heater hose from a 99-04, and some rtv. Pics attached where the rtv goes. Should give you around 10hp
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Old 05-27-2013, 09:52 PM   #14
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Also you will need to tap a new hole in the pi intake manifold aluminum crossover for the coolant sensor
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Old 05-27-2013, 10:15 PM   #15
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Sorry to ask this but where do I tap it? Thanks for the pictures it makes it much easier.
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Old 05-27-2013, 10:18 PM   #16
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Right sensor. The gray one
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Old 05-27-2013, 10:22 PM   #17
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I use the same sensor that is already on my intake correct? Just tap it and put it in?
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Old 05-27-2013, 10:26 PM   #18
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Exactly
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Old 05-27-2013, 10:54 PM   #19
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Good deal thank you for the help. One more question when it says fill in the water jackets what does that mean?
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Old 05-27-2013, 11:00 PM   #20
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Put rtv on the ports. Where I marked in red. Only need to put rtv in those 2 places.
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Old 05-27-2013, 11:05 PM   #21
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Gotcha thanks for all the help guess, this forum is a lot more helpful then the other one I have been on.
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Old 05-27-2013, 11:11 PM   #22
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This forum is nice because it seems like it is mostly a bunch of backyard mechanics just helping each other out vs ******* elitists on some of the bigger forums although they can spring up anywhere. There are internet racers and "know it alls" on here like everywhere else but its not as bad as the corral or stangnet for example.
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Old 05-27-2013, 11:13 PM   #23
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Exactly man, the other forum said I had to swap heads to put a pi intake on a npi and they left it at that. Glad I posted it here and hopefully I'll be doing the swap soon!
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Old 05-27-2013, 11:18 PM   #24
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Hmmm, sounds like a bunch of winners. I can't see that on any of the forums I frequent. Even the Corral will tell you "omg search" (and they are kind of right since that forum has almost 15 years worth of threads you can search) but the right info will be there.

I'd google this kind of stuff too if I were you, you might find it is a very common thing and you don't even have to go to a mustang forum to get the info. The PI intake swap is one of those things, almost EVERYONE who has a NPI car looks to do this swap if they are just going to drive the car as is and not get into swapping a whole PI motor or top end in. The NPI stuff really is that bad, its almost like Ford purposely made the first modulars so terrible so they could introduce the PI stuff in 99 and make it look that much better... hmmm...
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Old 05-27-2013, 11:21 PM   #25
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Yeah I'll be doing more searches once I get the intake to do, this way I know I am doing it right and not going to mess anything up.
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