Intake Manifold Air Valve Bolts? - Taurus Car Club of America : Ford Taurus Forum
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post #1 of 12 (permalink) Old 05-09-2018, 10:29 PM Thread Starter
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Question Intake Manifold Air Valve Bolts?

Hi friends

I hope you're all doing well.

I recently noticed my upper intake manifold had some holes in it, causing a nasty vacuum leak. I ordered a new Dorman upper intake manifold and attempted to install it today.

When attempting to switch this valve to the new intake ( apparently it's an Intake Manifold Air Valve XW4E-9L490-AD ), both bolts stripped on the actual hex part of the head. They basically "rounded", not allowing me to get a good grip to turn them into the new intake.

Does anyone know where I could find 2 OEM replacement bolts for this valve? The guy at the hardware store looked at me like I was crazy when I brought them in.

Thank you so much

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post #2 of 12 (permalink) Old 05-10-2018, 02:48 AM
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What's wrong with the bolts shown becaused it looks ok to me. It is a Torx type bolt. Try a JY if it really is damaged.
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post #3 of 12 (permalink) Old 05-10-2018, 06:59 AM Thread Starter
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Automender12345 - I really appreciate the response.

Are they standard Torx sizes? Because none of my small set of allen wrenches seem to fit just right.

I think because of this, I (foolishly) used a size that was slightly too small and certainly didn't fit perfect. It caused the grooves in the head of the bolt to round more than they should be, not allowing any allen wrenches grip inside enough to turn it.

Definitely plan on calling tons of JY's today - good idea thank you.

What is the best way to describe these specific bolts to the person on the phone? Haven't dealt with JY's too much but something tells me now I will be
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post #4 of 12 (permalink) Old 05-10-2018, 09:25 AM
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What you are trying to do is make an Allen (a.k.a. hex head) wrench work on a Torx head screw. They are not interchangeable. Before running around trying to find replacement screws, go buy some Torx wrenches. I'm not 100% certain on size as I have the Durotech engine and I don't readily see a valve like this in which to confirm...but, Ford usually used a T25 or T27 for these kinds of parts. Maybe someone can else can confirm.
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Last edited by MERCrunner; 05-10-2018 at 10:25 AM.
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post #5 of 12 (permalink) Old 05-10-2018, 11:48 AM
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^^^^^ +1

Pick up a set of Torx sockets at your local Harbor Freight for a few $$.
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post #6 of 12 (permalink) Old 05-10-2018, 12:03 PM
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Quote:
Originally Posted by Jeff K View Post
^^^^^ +1

Pick up a set of Torx sockets at your local Harbor Freight for a few $$.
Agree 100%, Torx wrenches are essential for today's cars, no matter the brand. They are for the convenience of making things in a factory. Stronger and they stay put on the wrench. Philips was designed to let go and not overtighten screws. The sizes are a pain because often more than one size will look to fit but the smaller one is not good. I have to try the size until I find one too big and back down one size.


-chart-
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post #7 of 12 (permalink) Old 05-10-2018, 12:08 PM
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This is what you need.

https://commons.wikimedia.org/wiki/F...20-T25-T30.jpg



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Last edited by Automender12345; 05-10-2018 at 12:11 PM.
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post #8 of 12 (permalink) Old 05-10-2018, 03:32 PM Thread Starter
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MERCrunner , Jeff K , chartmaker , Automender12345

Thank you so much for your responses - and my noobie-ism is embarassing lol. As you can tell, clearly a beginner but I'm committed to learning.

Just picked up a set of Torx sockets at Harbor Freight and completed the job - she's purring like a kitten

You guys are amazing and I really appreciate your help
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post #9 of 12 (permalink) Old 05-10-2018, 03:46 PM
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You certainly aren't the first to confuse the two...and, won't be the last. Kudos for asking questions and seeing the project thru. It's how we all learned...and, continue to learn.
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post #10 of 12 (permalink) Old 05-10-2018, 04:38 PM
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If your catalytic converter is plugging that maybe sending too much exhaust gas to the EGR and melting your intake. Make sure your PCV valve is working because it lets air into the EGR inlet region and helps keep the area cool. My 2006 shows signs of light melting and I don't have any issues.
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