If you just do the passenger side you should not need to remove the turbo. I also had to do this a few years ago. Its pretty straight forward, just takes time.

Make sure to use the mortorcraft gray rtv. Its good stuff.

How did you discover the leak? Are you sure the drivers side isn't also leaking?

 

I pressurized the Intake tract with compressed air. I could hear air hissing out, sprayed soapy water and it started hissing and making bubbles.

 

Where can I buy new stock plenums?

 

I can just leave this here...

Riffraff Diesel Billet Intake Manifold Plenums for Ford 7.3L 94-03

 

Says it won't fit with stock turbo. I have a stock turbo and E99 spider. My stock plenums lasted 20 years. I'd like to go back with stock if they are available.

 

Intake Plenum Manifold Cover - Early 99 - Riffraff Diesel Performance

You might call them to see when they will be back in stock.

Why do you need to buy a new one? Why can't you reuse the old one?

 

Just seems like parts like that get tweaked when removing them, then they leak. When I remove old parts, I like to go with new stuff it oem is available.

 

F6TZ9E434BA OEM GENUINE FORD FACTORY COVER NEW | eBay

I didn't realize that Riffraff must not make them for 2" plenums. My bad lol

 

I bought that eBay plenum. Can I buy that gray silicone at Ford, or can I use "The Right Stuff?"

 

NO Rightstuff! It's not even close to the same thing as motorcraft rtv!

I bought my motorcraft rtv from RiffRaff, I'm sure Ford has it, but who knows how much it'll cost you.

 

I got mine off Amazon its a small tube but it goes a long ways.

Sent from my Super awesome outdated Samsung that doesn't burst into flames using Tapatalk

 

Yes you can buy the rtv at ford or order it. Either way make sure to use the mortorcraft stuff. Its awsome. You will need a caulk gun to apply it.

 

To explain how good the stuff is, when I had to remove my oil pan, it took 3 big prybars and a screwdriver just to get the oil pan off. It's NO JOKE.

 

The intake sealant is Motorcraft TA-30, comes in a stubby caulking tube. Its the stuff to use to seal against high boost pressures. Cost me $25 net at the dealer a month ago. Maybe use a 1/8" bead since if you use too much, a lot oozes out into the interior of the plenum where you can't see it.

When removing the plenum, one of the bolts holding the intake plenum can't be unscrewed fully. Just loosen it up until it hits the front cover after taking out the rest of the bolts The bolt hole for the last bolt is slotted for removal/install. Loosen the plenum and then wiggle it out from under the last bolt.

Motorcraft TA-31 is the stuff for the rest of the engine.

I use TA-30 for everything. LOL

Have pulled the pan sealed with it several times without much problem or deforming the pan. The trick is to use a stiff putty knife about 1-1/4" wide and hit it with a hammer to cut along the sealant seam. Sharpen the edge first. Putty knife works great. A little hard to get started but once you get the putty knife cutting, its easy. Use a thin blade screwdriver for the curved part. Pound it in in successive spots, cutting the sealant. Then pop the pan loose.

 

Forgot to say its a 1/8" bead on the pan rails and 1/4" bead on the round sections.

 

Are you referring to the oil pan? Just to clarify....if the one bolt cannot be removed and the plenum slid out, then how do you reinstall it without smearing the caulk bead?

 

Yes on the pan.

The bolt hits the front cover since its too long to be removed. There is enough clearance to lay a bead of sealant and still get the intake plenum in there. Lay a continuous 1/16” or so bead and also encircling each bolt hole. Tilt the intake plenum and put it under the bolthead while holding the plenum up as much as possible. Then lay the intake plenum on the sealant bead.

Its easy using the sheet metal intake plenums. I did it using thicker billet aluminum intake plenums without any problems.

 

I guess its just something you gotta pray comes out okay after it dries? Lol

 

Thanks! Put the silicone on the head surface, not the plenum?

 

Yes, form the bead on the head surface.