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Old 07-19-2014, 10:14 PM   #1
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What parts for intake swap?

My used 2002 GT came with the crappy Dorman NPI intake. There is nothing physically wrong with my intake, but my car feels very restricted and rich, and "gritty" lol.

I want to swap it out with the Ford PI intake. But will I need a different alternator bracket? I have read that the Dorman requires a different alternator bracket, so if I go back to the stock intake, do I need a different bracket?

Are these the correct parts?:
Amazon.com: Ford Racing M9424P46 Intake Manifold: Automotive
and
Amazon.com: Fel-Pro MS92121-3 Manifold Gasket Set: Automotive

Do I need anything else?
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Old 07-19-2014, 10:28 PM   #2
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Just got done installing the ford PI intake manifold. I reused the old alternator bracket and just drilled new holes for it to mount to every thing. That is all you need to swap them out. Fairly simple to change these too. Just make sure you follow the pattern to torque it down properly.
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Old 07-19-2014, 10:42 PM   #3
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Take a pic of the bracket you have, probably can use it. x1000 on making damn sure you torque it right and in the right sequence. 22 ft lbs is the torque value and you can get the sequence from a simple google search. Fel pro gaskets are the only gaskets you want to be using here.
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Old 07-21-2014, 07:25 PM   #4
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heres some pics of my alternator bracket. It says FORD on it, with a part number. I just need to know if it is compatible with the stock intake manifold linked above... also, do I need a new thermostat gasket? any sort of "nipple" that Ive read about for heater hoses or whatever? o-rings for injectors?

Id like to have all needed parts so that I can do a full swap in one day and drive the car to work the following day.

I have a torque wrench, a decent selection of tools, and quite a bit of wrenching experience.

Any other info about recommended parts are appreciated.
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Old 07-21-2014, 07:49 PM   #5
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That bracket is fine for the FRPP intake.
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Old 07-21-2014, 08:30 PM   #6
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cool. thanks. Anything else I should know?
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Old 07-21-2014, 08:44 PM   #7
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Yeah, do the tstat while its apart, only use fel-pro intake gaskets, torque of the intake bolts is 22 ft lbs and work from the middle out, there are torque pattern pics on google images.

Also if your COPs are old now is a good time to rebuild them and do the plugs if the plugs haven't been done in awhile. These cars love Autolite 103 coppers and torque on the plugs is 12 ft lbs. Yes, you NEED to use a torque wrench when doing the plugs.
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Old 07-21-2014, 08:45 PM   #8
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Yeah, do the tstat while its apart, only use fel-pro intake gaskets, torque of the intake bolts is 22 ft lbs and work from the middle out, there are torque pattern pics on google images.

Also if your COPs are old now is a good time to rebuild them and do the plugs if the plugs haven't been done in awhile. These cars love Autolite 103 coppers and torque on the plugs is 12 ft lbs. Yes, you NEED to use a torque wrench when doing the plugs.
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Old 07-27-2014, 12:04 AM   #9
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Ok this might be a stupid question but how can u tell which intake you have? Pi or non pi? Here's my 02 GT alsoClick image for larger version

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Old 07-27-2014, 12:25 AM   #10
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02 should be the PI unless someone has replaced it with something like a dorman at some point. If It's factory I would assume It's the PI. I'm sure someone will chime in with a way to identify it by codes on it etc.

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Old 07-27-2014, 10:28 AM   #11
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you can tell by the front runner
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Old 08-03-2014, 07:28 PM   #12
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Just completed the swap and want to update this thread.

I followed the advise given here. I used Fel Pro gaskets and I was very impressed! I guess I was expecting a standard oiled cardboard type gasket, but thats not the case at all! these gaskets are a thing of beauty. the are molded plastic with integrated o-ring seals and even have mounting tabs to fit into the heads in the exact right position.... I have nothing to compare them to as this is the first time I've bought intake gaskets, but im thoroughly impressed!

The Ford PI intake fit perfectly, of course, and even smoothed out my gritty acceleration problem.

My old alternator braket on the Dorman was a perfect fit on the new intake with no modification needed.

The whole project took about 3 hours and included a couple runs to the auto store for COP bolts and coolant. All-in-all, not a hard job and I did it in an afternoon after I got home from work with basic handtools.

I left the battery unplugged during the whole job so it could relearn parameters after it was back together. I drove it for a good 30 minutes for the computer to recalibrate to the new intake, then I took a timed speed run of 0-60 to compare to my old runs with the Dorman.

The results were not was I was expecting. The new intake made no improvement to my lousy 0-60 times, but at least its smooth running, and it even sounds meaner.
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Old 08-04-2014, 05:41 PM   #13
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I have a 96 would this be about the same swap as what you did or do I have to alter the alternator bracket?

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Old 08-04-2014, 06:19 PM   #14
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Sorry, but i cant give you an answer about that.
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Old 08-04-2014, 06:36 PM   #15
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Quote:
Originally Posted by jefx View Post
Just completed the swap and want to update this thread.

I followed the advise given here. I used Fel Pro gaskets and I was very impressed! I guess I was expecting a standard oiled cardboard type gasket, but thats not the case at all! these gaskets are a thing of beauty. the are molded plastic with integrated o-ring seals and even have mounting tabs to fit into the heads in the exact right position.... I have nothing to compare them to as this is the first time I've bought intake gaskets, but im thoroughly impressed!

The Ford PI intake fit perfectly, of course, and even smoothed out my gritty acceleration problem.

My old alternator braket on the Dorman was a perfect fit on the new intake with no modification needed.

The whole project took about 3 hours and included a couple runs to the auto store for COP bolts and coolant. All-in-all, not a hard job and I did it in an afternoon after I got home from work with basic handtools.

I left the battery unplugged during the whole job so it could relearn parameters after it was back together. I drove it for a good 30 minutes for the computer to recalibrate to the new intake, then I took a timed speed run of 0-60 to compare to my old runs with the Dorman.

The results were not was I was expecting. The new intake made no improvement to my lousy 0-60 times, but at least its smooth running, and it even sounds meaner.

Did you do the Full PI swap?.. Or just the intake?..


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Old 08-04-2014, 07:15 PM   #16
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its an 02
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Old 08-05-2014, 01:29 PM   #17
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Swapping a 96-98 car with NPI heads to the PI intake is not the same as a basic intake replacement. Google "PI intake swap" for multiple how-to threads.
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Old 08-05-2014, 04:24 PM   #18
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There are videos on the internet showing a 5-6hp increase from Dorman to the ford racing manifold. Not enough to matter for a daily driver really, save your money.
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Old 08-06-2014, 12:00 AM   #19
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Thanks for the info. I would more than likely do the whole swap then in that case to make it worth while. Better yet I more than likely will be buying another mustang in the next couple years.

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Old 08-06-2014, 12:34 AM   #20
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Thanks for the info. I would more than likely do the whole swap then in that case to make it worth while. Better yet I more than likely will be buying another mustang in the next couple years.

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I did the pi intake swap on npi heads and it made a pretty noticeable difference. Its one of the best bang for your buck mods for 96-98 gt's. I'd say it was more like 10-15 hp, even more when tuned.


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Old 08-06-2014, 07:10 AM   #21
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There are videos on the internet showing a 5-6hp increase from Dorman to the ford racing manifold. Not enough to matter for a daily driver really, save your money.
Plz reference said videos.
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Old 08-06-2014, 08:01 AM   #22
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I installed the dorman used same alternator bracket that the car came with. The box came with a bracket. But didn't need it. Kicking my self I the but now buti that dam thing. So goin to wait till I fix my problems first. Then but the pi one.


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Old 08-08-2014, 12:10 AM   #23
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Plz reference said videos.

first 3 pulls are with the Dorman
last 3 pulls are with the ford racing intake
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Old 08-08-2014, 06:47 AM   #24
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first 3 pulls are with the Dorman
last 3 pulls are with the ford racing intake

Fom that chart I'm seeing up to a 10rwhp gain over the Dorman from an auto car with no other changes (248-258 both on the second runs respectively). PI intake is $50-$60 more than the Dorman brand new. If you don't think 10rwhp for $50 is worth it for a bolt on 2V you are nucking futs.

Even if we are talking about replacing a Dorman one has already spent money on, $215 for 10rwhp that you can do in an evening is still very worth it.
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Old 08-08-2014, 12:06 PM   #25
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1. First Run - Gains 5.57 HP and 6.68 tq
2. Second - Gains 9.81 and 1.45 tq
3. Third Run - Gains 5.32 HP and 3.91 tq

Not sure of the math or dynos or averages but I don't see an easy 10rwhp gain from this. IF your building your car up then of course it is worth the time and money hands down not arguing that at all! If you already have a dorman and your car is a dd you shouldn't loose sleep. Your not loosing 20 hp and 20 tq as I have read on this site.

But as Scotty says for $50-$60 more than the Dorman you could have the proper intake. And would kind of be stupid to cheap out when doing the replacement since we all know at some point we had to or will have to replace the crappy stock one that IS going to crack
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