1996 4.0 intake gaskets.

[travisgm]

I started to take apart my intake to get rid of my P0171 and P0174 codes on my truck. Everything is going fine with disassembly My only concern is that the previous owner told me that all work was done by a ford dealer but what I’m seeing inside doesn’t really jive with that.
When I removed the Plenum, I see the 3 rubber gaskets in the plenum but, I also see a paper fel-pro gasket on top of the fuel rail with what looks to be “ultra-copper” silicone on both sides.
Below the fuel rail there is what looks to be a ¼” spacer with paper gaskets on both sides.
I bought the Fel-pro upper intake gasket kit and it has the 3 plenum gaskets, egr O-ring and thick gasket for below the fuel rail. Also to get this “kit” I had to order it for a 97-98 ranger. Mine is a 96.
My question is, do I need the thin gasket below the plenum gaskets?
Also, what’s the trick for removing the fuel injectors from the intake?
I got the fuel rail off easily by rocking it as I lifted. I have tried with lots of effort, almost to the point of feeling like I’m about to break something, rocking and pulling on the injectors but, they just won’t pull out.
Another worrisome issue I’m seeing is that I really don’t see any place that wasn’t sealed. I’m wondering if I am “fixing” something that wasn’t the issue. If the problem codes still exist, what’s my next most common culprit?
I plan on replacing the vacuum lines that look “dry” anyway.

 

[spraymonkey]

u shouldnt have a gasket below the plenum, thats what the 3 single rubber gaskets are for on the plenum to seal against the fuel rail, but u do have two gaskets that go on the 1/4" spacer. not sure about the 97-98 maybe u got the SOHC kit, ive had idiots screw up my kits as well just see if they match up and you should be alright. use some penetrating oil and pull like a mother f'er i had a hard ass time with mine as well thought i was gnna rip the skin off my fingers lol, i also think they sell/loan a tool for removing injectors as well if you dont feel comfortable using bent pliers or a screw driver.

As for your codes could be a few things, Dirty MAF, Fuel Filter, Faulty 02, Exhaust leak up stream of the 02, and vacuum leaks. You should run injector cleaner at least once a month through your system to keep your injectors spraying good. I Not sure why someone would put a thin gasket beneath the plenum gaskets kind strange, did you hear and sucking noises when ur engine did run?

 

[travisgm]

Is it possible to buy the two gaskets that go on the fuel rail seperately? All I'm seeing it the kit and I really don't need any more than the 2 gaskets I'm missing.
I run injector cleaner already.
The only reason I am pulling the injectors is that they are the originals and I assume ass soon as they move in their housing the o-ring won't seal up again. I got them out now. I put a drop or two of oil on them and gave them a "wiggle" and then let them soak for a couple days. Now they pop right out.
For the amount of km's on the engine, they look nearly new. I was surprized.

 

[spraymonkey]

http://www.1aauto.com/1A/EngineGask...opping&utm_source=google_base&utm_content=EGS

http://www.am-autoparts.com/Ford/Ra...opping&utm_source=google_base&utm_content=EGS

found these fairly quickly. Just look around on the interwebs

 

[travisgm]

I bought the MS90732 (Fel-Pro). kit because after explaining to the parts guys at the desk, they couldn't find the gaskets for below the fuel manifold.
In that kit, there is a gasket that looks right close to the one that was removed (minus the blue ring of sealing material around the ports). There are the 3 plenum o-rings and egr o-ring.
You said earlier that I needed 2 thin gaskets that go on either side of the 1/4" spacer I have now.
The links you assed only show the one gasket. Maybe it's a newer version that doesn't look like the older ones?

http://www.oreillyauto.com/site/c/d...ck=Search_04727_1119631_-1&pt=04727&ppt=C0026
I found these and have them ordered, getting them tonight. They look the same as what I removed. It also l looks just like the one that had the ultra copper on it between the plenum and the fuel rail.
There is a couple things striking me as odd from the description on the link. It says it up to 1995 4.0L's, mine is a 96. The first set I had was for a 97 and up. What happened to 1996?...
Also, the verbal description of the gaskets says they are a "Fel-Pro - Plenum Gasket Set". if that's the case, why two, when one would do? If it's the fuel manifold/ rail gaskets, then call them by the right name...

 

[spraymonkey]

Hah i dnt realize that sorry didnt mean to mislead you, you need due because of the mating surfaces as for plenum just seems dumb to me, if you know what your looking for i wouldnt worry so much about the name, just match up your gaskets if they look the same ur good if not bring em back and bring i n your old upper intakes, ive seen them called upper intakes, lower plenums, plenums its really stupid i think some dont know what they are and are just trying to sell them to make cash. As for the ultra copper it shouldnt be there u dont need to silicone your upper intakes and ple nums gaskets, well the upper intakes are for the spacer and the three seperate two hole rubber gaskets are plenums u shouldnt have anything else below that.

 

[travisgm]

The thin gasket pair that goes on both sides of the spacer below the fuel manifold is Fel-Pro #MS94683 should anyone find themselves in my shoes.

So to do the job, you'll need the plenum o-rings, egr o-ring, fuel injector o-rings (just because you're there already and they will move when you take the fuel manifold off) and the two thin gaskets on both sides of the rail.

 

[97RangerXLT]

I have done an upper engine gasket how to... i wish i saw this earlier...let me get you the link.

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[97RangerXLT]

http://www.therangerstation.com/forums/showthread.php?t=94437

There ya go

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