As I mentioned RAVE has nothing about removal etc of the inlet manifold, anybody know if the Haynes Mustang 1994-2004 manual will be any help? I'm not a great fan of Haynes but I'd be happier with some guidance.

https://c1.staticflickr.com/3/2853/3...0c839b8b51.jpg

I have just had a look and there a couple of pages and that includes the DOHC but the most useful part is the tightening sequence. It is all basic stuff. Undo A followed by B ect ect.

Shame you are so far from me or I would pop over and give you a hand.

I will have a go at scanning the relevant pages if you want to send me your Email address.

You have a PM Steve.

Lots of videos on Youtube!
Here's one of them!:-)

https://www.youtube.com/watch?v=US3FIJXi44o

Join a mustang forum, they probably have "how to's" just like we do.

That's the best video I've found. Stumbled across it by pure chance, the title doesn't aid finding it. Currently waiting for a pair of gaskets.

I've looked at various Mustang forums but haven't seen any with a "how to" section.

I carried out the temporary repair Rich mentions which was still going strong 3 weeks later when I had the manifold replaced, I threaded and glued followed by jb welded the outside for additional 'metal' support but appreciate if you have the manifold, I would have done it right the first time, but as my daily driver I had to get it done whilst cycling 13 miles each way either end of a 12 Hour shift LOL. Good luck with it, can't be nice when you're feeling Carp too :(

I did a temporary repair but it isn't filling me with confidence. I don't use the car a lot so I'll just wait for the gasket set to land and swap the manifolds. Besides, not having the car is getting me off my ass for a bit of exercise!

I'm thinking of possible ways to reinforce the connector on the "new" manifold and (hopefully) avoid ever having the problem again.

The manifold has been lying in the shed since I bought it over two years ago. I hummed and hawed about buying it (£200) until I started tallying up the value of all the bits attached to it.

I'm not sure it needs it really Steve. .. the new one I mean it's a combination of age deterioration and possibly over tightening. I don't remember the exact size now but an interior metal sleeve lie you slip in the modern poly prop water pipe fittings would probably help. ..although they are too small from my vague recollection but an internal sleeve would aleviate any possibility of over tightening and hence crushing the pipe onto the spigot. ...

But If careful I think t will be fine for years to come :)

Sent from my SM-N910F using Tapatalk

Somewhat variable internal diameter on mine ! Max 14.9, min 14.6 mm. Maybe due to some over-tightening in the past causing the pipe to "neck" a couple of cm down ??? It broke off not far above that minimum point.
The broken off piece crumbled when just pressed between thumb and forefinger!

David

Could it be it doesn't like red antifreeze? 2004 red antifreeze wasn't as comen as today and is more aggressive I think?