Car Problem Reports

Ford Explorer Vacuum Leak From Intake Manifold O-Ring Gaskets

Ford Explorer Problem
66 Reports
Me Too

Model Years Affected: 1995, 1997, 1998, 1999, 2000, 2001, 2002, 2004, 2006, 2007

Engines Affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8, 5.0L V8

Average Mileage: 131,332 mi (27,534 mi - 245,500 mi)


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

  • , , 4.0L V6 SOHC, 124,652 mi

    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.

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  • , , 4.0L V6 SOHC, 54,000 mi

    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.

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  • , , 4.0L V6 SOHC, 61,000 mi

    rough starting only when cold, runs rough for 5 min and then is fine once it warms up.

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  • , , 4.0L V6 SOHC, 148,000 mi

    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.

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  • , , 4.0L V6 SOHC, 245,500 mi

    Rough running, stalling, extremely low gas milage.
    Purchased intake gasket kit planning to install this week (10-8-11)

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  • , , 4.0L V6, 130,000 mi

    poor idle rough running engine light on misfires on 1 and 2 cylinder in shop now

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  • , , 4.0L V6 SOHC, 142,000 mi

    repair was 350$ at dealer- upper and lower intake gaskets replaced

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  • , , 4.0L V6 SOHC, 140,000 mi

    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.

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  • , , 4.0L V6 SOHC, 128,000 mi

    600.00 to fix by a ford dealer, sounds high to me

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  • , , 5.0L V8, 90,200 mi

    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?????

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