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(More customer reviews)After over 100K miles (and days after having replaced a coolant leaking intake manifold gasket) on the second plastic cross over manifold on my mustang I noticed a small crack near the passenger side temp sensor that was weeping coolant and upon disassembly a three inch crack in progress where the cross over was getting ready to burst.
I did not want to pay the outrageous prices ford dealers charge for NPI aluminum cross over intake manifolds nor do I like any of the solutions to use a PI manifold on NPI heads (due to cost and/or engineering reasons depending on the method) so I went with the dorman hoping for the best.
On the plus side the manifold is made in the USA, it fits, and the install of the manifold itself doesn't have any special issues to deal with. It's far cheaper than what ford dealers charge for the NPI manifolds. (Ford PI manifolds can be found for just a little more than what this Dorman manifold costs)
On the minus side the molds that make the pieces at the intake ports were designed with a parting line inside the ports. The resulting draft creates material that will block some of the airflow or cause less than ideal flow. There was also some flash in there on the part I got. I removed this material with an xacto knife and a dremel to smooth out the ports. This clean up made it much more like the ford manifold. It was far less material than seen on dorman manifolds for other applications and probably would not make much difference, but I didn't like it so I took care of it.
The included alternator bracket does not work on a mustang. It interfered with the tubes that go across the top of the manifold. My dremel and a bench grinder were used to cut away the big 'plate' that was on the dorman bracket but not the OEM one. Also be aware that if your car has COP the coils are held in place by thread cutting screws instead of having threaded inserts. Mine doesn't so that wasn't an issue.
I haven't driven the car much with the dorman manifold on so I can't say if there has been any change in power. it seems to be about the same, maybe a little less, but from what I could find on the mustang and crown vic forums that the NPI dorman vs. NPI ford is the same power wise.
Also of note, if leaking coolant has caused any additional wear-and-tear on some of the spark plugs or the coils have gotten weak with age (or both in my case) upon re-assembly misfires of some degree will make themselves known even if there were no obvious problems previously. If misfires show up after wards check the gap on the plugs that were flooded with coolant and the coil packs. Also check for boiled down coolant sludge inside the spark plug boots.
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