I have the lower intake loosened partially, but it’s stuck toward the middle-back. Mine has grey sealant all over. It’s very squishy and doesn’t seem to be too much of a problem, but something isn’t letting go. I’ve removed all the 13mm bolts, gas line and fuel injectors connections. Also the smaller rigid coolant line that had to be pulled out. There’s an o ring on it I need to find. I guess it’s the outlet since I know which pipe is the coolant inlet. I know there are locating pins that might be grabbing it. I’ve watched the AB head gasket videos. I haven’t removed the valve covers yet, but maybe they’re in the way a bit. Anything else that will help? It’s lifting up in the front to the middle, but it’s on there.

 

The valve covers sit over the lower intake.... You must remove at least one to pivot it out.

 

Thanks I’ll remove the valve covers. I was following the AB video and they didn’t remove them first, but mine seem to be interfering. I’ll look at the rockers and see if I notice anything that might be off. I’ll know get to that point and wonder if I should redo the head gaskets too.

 

That's odd. Since Sunday evening I've removed two intakes from both a 99 4.0 and an 03 4.6 without removing the valve covers.

I did have to use a pry bar to gently convince my intake to break loose from the gasket as both had sealer on them. I lifted on the driver's side first and once loose pulling off the passenger side was a non issue.


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Was it a grey gummy sealant on the lower intake and possibly the heads? I wondered if it’s how they were sealed at the factory. I’ll try it again later. I didn’t want to pry up too hard and break anything. That aluminum can be brittle. I’ll just remove the valve covers since I need to do that anyway.