Vacuum Leak From Intake Manifold O-Ring Gaskets on Ford Explorer

The intake manifold O-ring gaskets commonly leak, causing stalling and poor idle quality; the Check Engine Light will illuminate.

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Average mileage: 134,309 (27,534–245,500)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8, 5.0L V8
11 model years affected: 1995, 1997, 1998, 1999, more2000, 2001, 2002, 2004, 2005, 2006, 2007
75 people reported this problem
29 people shared problem details
1998 Ford Explorer- 4.0L V6 SOHC124,652
Our 1998 Exploder has been doing this for several years, only the initial start of the day (ALWAYS does this when it gets cold, and worse as it gets colder)turn the key and it sputters and has troubling staying running for a few minutes, you have to nurse it to keep it running. I had replaced all the sensors over the years, new fuel filters, pump, and on and on...threw $100's of dollars at it, it never popped a code to tell me what was wrong with it...took it twice to the Ford dealer and all they could do is scratch their heads and tell me "We are not sure", this past weekend I took the intake apart and cleaned out all the carbon and other gunk in it, used a (1/2 gallon of lacquer thinner and 3 cans of carb cleaner) put in NEW, upper and lower intake gaskets, put it all back together, and it started right up, and now it acts like a new motor, it has a lot more giddy up to it. This morning it was in the upper 30's and it popped right off and ran like it never has in the past few years. So, yep, I fixed it! It took me about 4 hours to accomplish it. Worth every dime and hour spent..oh yeah the gaskets were only about $25...sure wish I had known about this a long time ago.
2000 Ford Explorer- 4.0L V6 SOHC54,000
Vacuum leak from intake manifold O-ring gaskets. The intake manifold O-ring gaskets leak, causing stalling and poor idle quality; the Check Engine Light will illuminate. Only happens while engine is cold. Gaskets seal after engine warms up.
2001 Ford Explorer- 4.0L V6 SOHC148,000
2001 explorer sport, stalls out when cold. runs ok after warm up but.engine light is always on with three problem codes, have already had new plugs and wires,fuel injector replaced, intake manifold gasket, MAF sensor, and idle control. still have the problem and codes. mechanic says he needs to do a "smoke" test. running out of patience and money.
2000 Ford Explorer- 4.0L V6 SOHC61,000
rough starting only when cold, runs rough for 5 min and then is fine once it warms up.
1999 Ford Explorer- 4.0L V6 SOHC245,500
Rough running, stalling, extremely low gas milage. Purchased intake gasket kit planning to install this week (10-8-11)
1998 Ford Explorer- 4.0L V6 SOHC140,000
Rough idle, no check engine light or codes set. Scanned and got readings of 0 volts all O2 sensors, all fuel trim values were -100. Replaced intake manifold O-rings.
2001 Ford Explorer- 4.0L V6130,000
poor idle rough running engine light on misfires on 1 and 2 cylinder in shop now \
2007 Ford Explorer- 4.0L V6 SOHC119,000
rough idle and dies whenever i come to a stop and or start the car... seems to run fine when you drive and accelerate although as it warms you begin to feel hesitation upon acceleration...also there is a distinct hiss. hiss. hiss hiss. hiss....sound coming from the area of the intake so... my initial thought was the intake manifold... however on a diagnostic test it pulled codes for a faulty egr valve and a failed cam shaft sensor... replaced those as well as the maf sensor and I still have the same problem... so it brings me back to my original thought of it being a cracked intake... sealed the joints of the intake manifold with jbweld and replaced the O rings... result .... same problem..... Is it possible for these intakes to crack on the inside? because i still believe its the manifold that is the problem... I just have spent too much on parts i didnt need thus far, and would like to feel more confident that its a manifoldcrack on the inside before i spend the $400 for a new one...
1999 Ford Explorer- 5.0L V8
rough idle and check engine light on!
1998 Ford Explorer- 4.0L V6 SOHC142,000
repair was 350$ at dealer- upper and lower intake gaskets replaced
1998 Ford Explorer- 4.0L V6178,000
when cold engine will not idle on its own you have to set with foot on gas or it will cut off
1998 Ford Explorer- 5.0L V890,200
Dealership stated about $500 to correct but may have other issues once they are pulled off. Also needs all new plugs and wires, another $500. With additional testings dealer has padded the bill to $1800. Is this SUV worth it?????
shop cut and then welded new pipe to solve problem without replacing entire system
1999 Ford Explorer- 4.0L V6 SOHC128,000
600.00 to fix by a ford dealer, sounds high to me
Was a code p0106 has misfire and ideals rough
2004 Ford Explorer- 4.0L V6151,515
i changed my intake and the oring did not fit even afer buying a new one
137000 mi it just died on me now costing almost 2000 dollars to repair
2000 Ford Explorer150,000
intake manifold o ring gaskets are in need of replacement. I continually have various and numerous problems with fuel system. Is this typical for 2000 ford explorer sport 4x4. Have been pumping too much money into repairs and was hoping to get 300,00 miles on it!! I really do not want to buy a new one. Any ideas or suggestions??
2006 Ford Explorer- 4.6L V875,000
Rough idle and ticking noise at startup along with engine stall with no load when cruise control is engaged. Replaced upper and lower intake manifold gaskets. Problem solved!
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