Lower Intake Manifold Gasket Leak

CEL came on for my wife's 2000 Windstar - 3.8L. She took it to Ford, they said the lower intake manifold gasket needs replaced - $350USD.

Trying to save money, I took it to a more trusted shop. They offered a different view - maybe because they didn't have the error codes that Ford cleared out. Anyway, they saw oil 'pouring' out at the throttle body. Also they are aware of TSB 03-16-1 and recommended doing that instead. They didn't see the problem with the lower intake manifold gasket, but $500USD would correct the problem they saw. Unfortunately the bill ($$$) is going in the wrong direction!

I did some research online, called Ford to see if they had recorded the original error codes in their files - go figure, they didn't - but the tech assured me that they were probably lean bank 1 and lean bank 2 - aren't these the infamous P0171/P0174 codes? I mentioned the TSB and he said 'no' the problem I have is different. Is it?

So my question is ... are these really all the same problem or should I seek a third opinion?

Your help is much appreciated!

It sounds like the tech at Ford is providing conflicting/confusing information.

If he remembers the lean codes then yes they are the infamous 171/174 codes. The TSB states that if there are no other driveability concerns to go ahead and perform the TSB.

The lower intake manifold gasket could mean the port seals that are on the top of the lower intake or it could be the lower intake to block gaskets. Both could introduce the lean codes. I would suspect that the intake to block gaskets would provide other problems. Oil should not really be pouring out of anywhere.

I find it hard to believe that replacing the lower intake to block gaskets could cost less than the ports seals since more of the engine needs to be disassembled including the ports seal area to get to them.

I would recommend going back to Ford and ask exactly which part is going to be replaced (part number would be the most beneficial). Ask why the TSB is not the cure since you do not have other drivability issues (I assume that you do not).

Thanks for the advise. I will contact Ford again and post back here the reply.

I contacted the Ford tech who recommended the lower intake manifold gasket replacement. We discussed what he felt was the problem as well as TSB 03-16-01. He felt these were truly two different problems.

So should I:
1) Replace only the lower intake manifold gasket, per the dealer.
2) Do #1 and TSB 03-16-1.
3) See a third opinion.
4) Do nothing since the CEL hasn't come on since the problem was diagnosed.

According to the parts dept the numbers to fix per Ford's plan are: yf2z9439aa (LH & RH gasket to block - $10.93/ea) and xf2z9h486aa (six little o rings - $2.71/ea), though the guy said that the mechanics usually also request xf2z9461aa ($15.77) which is the upper clamshell gasket.

If you indeed do have oil coming out of the throttle body opening, it is most likely that oil is being sucked into the intake via the PCV line from the front valve cover assy. This would indicate that oil has deteriorated the upper gasket, isolator bolt seals etc. It might also have deteriorated the lower intake gasket though I'm not sure how your ford tech can diagnose that without actually taking things apart to that level. Since they will have to disassemble the intake anyhow to get to the lower gasket, I'd make sure they perform the TSB and if they replace the lower gasket make sure they can show you how/where it was leaking too.

I had the TSB problems last year. I actally only got p0171 and a CEL light, I read the code and erased it. It came back the following week, i erased it again and it never came back but the problems continued to get worse until I had it repaired. Oh, the oil contamination and gunk from the PCV line froze my intake runners and dmamged the runner controls as well..you might want to make sure yours are functioning at the same time.

Good luck