[FocusBoomer]

Car is in the shop to replace the PCV valve because engine is running rough and oil was seeping out the top of the oil filter. I also have the dreaded intake manifold flap rattle so thought I would replace that also. Bellow is the email I received when trying to order a new intake manifold from Ford. Now I am afraid to put the old one back in with the flap rattle because if it comes apart it could ruin the engine? Has anyone removed the flaps and ran with no flaps? Would that be preferred over running with rattling flaps?

Part # 4S4Z-9424-BKis currently on national backorder with the automotive manufacturer and has no estimated date of resupply. We do not currently have this item in stock at our warehouse and are unable to acquire it at this time. Unfortunately, despite our best efforts, sometimes the demand for certain parts and accessories exceeds manufacturers’ current supplies. I apologize for the inconvenience.

 

[amc49]

You can remove them of course but people report driving issues like bogging and lowered response with them out.

 

[WhatALemon]

I do not think you find an intake on Ford sites anymore but you should be able to find them somewhere.

 

[WhatALemon]

Also, "oil was seeping out of the top of the oil filer" - check your oil pressure sender switch as they can leak.

 

[FocusBoomer]

Thanks for the replies, I found one on Ebay and it's supposed to be new so we will see. I should have checked there before. There's also the possibility to replace the swirl flaps themselves if that falls through.

 

[WhatALemon]

I hope there is more than one out there as I will need another in the next few years.

noticed that some parts starting to get scarce for these cars...

 

[FocusBoomer]

I hope there is more than one out there as I will need another in the next few years.

noticed that some parts starting to get scarce for these cars...

Looked like a few of them there, yes starting to get scarce.

 

[BlueKoda]

I removed mine when I had my ZX3, didn't notice any performance impact.

 

[amc49]

Live in a cold state or warm?

 

[Merv]

I removed those swirl flaps a few years ago from my 07. I do not recall feeling much of a difference. Sometimes it seems like the low end torque is a bit low, but I am not sure if that is due to the flaps being removed. I also have a strange whistling noise, which is still there after removing the flaps and changing the PCV valve...

Looked like a few of them there, yes starting to get scarce.

I've been hearing that it can be difficult to get part even for new cars, due to backorders.

 

[Blokhead]

You could use an Escape manifold that does not have the "swirl flaps of death"! Part no. 5L8Z-9424-A. Still available for about $170 I put one on my '05 ST and do notice an occasional hesitation at light throttle when the engine is cold. This might also be aggravated by the fact that I removed the primary cat from the exhaust system resulting in less back pressure. My car had about 125K on it, and I think they looked worse than yours. Glad they're gone.

 

[FocusBoomer]

I was replacing some hoses while I had the intake manifold off and found a leak in my water adapter. The OEM replacement is plastic which I guess will be fine. I didn't like the way it looked with the holes in the top so made a cover out of some tin. I ended up with an aftermarket intake manifold so I'm a little worried but we'll see once I get everything back together.

 

[FocusBoomer]

I got everything back together and it was running good but then threw a P2004 (Intake Manifold runner control stuck open). That makes sense because I remember my IMRC solenoid had a piece fall off of it and I managed to stick it back on and it stayed but I guess that wasn't good enough, so I ordered a new one. Another thing was with the bottom bolt of the manifold wouldn't fit properly which I assume because it's aftermarket. No problem, I put in a different length bolt and it's holding good. All the top bolts where the gaskets are fit properly.

 

[WhatALemon]

If you ae missing the stock battery cover, I have one. I changed my battery tray to a later model and have a spare cover for that year. if you are interested, PM me and I will sell it to you.

 

[FocusBoomer]

The IMRC control solenoid didn't fix the issue so I transferred the original OEM actuator to the new manifold and that fixed it. I suspect that because the actuator has an electrical connection the aftermarket one wasn't completely compatible. The oil leak around the top of the oil filter is gone also so I suspect the new PCV valve helped with the internal engine pressure. Everything that was done is below at a cost of about $700. Glad to have it back on the road.

Air Intake Manifold
PCV valve and hose
Coolant reservoir and hoses
Water adapter
Battery
Oil Change and Filter