Can I assume it's ruined?

[Chief Master Sergeant]

Installing the metal heater hose piece into the aluminum intake and it started to thread in easy enough, but about halfway in it stops. I Didn't force it; just backed it out and looked at the threads. Looks like it cross threaded somehow, which makes no sense. This is 91Mustang lower intake. Can I assume this can't be tapped and cleaned up to work? I vacuumed out the port really well and into the hole where the thermostat goes. Couldn't see any metal in that hole, so I'm hoping nothing made it down inside the new head. If this is not repairable, I have the lower intake from the explorer donor, but nothing else. Upper was gone.

 

[Viperwolf1]

The explorer intake is better. I wouldn't spend the time repairing a mustang intake.

 

[blubuckaroo]

Try the tap. Why pull an intake manifold if you don't have to.
It's the curse of aluminum.
This is exactly why I don't like aluminum heads on Broncos. Header bolts are too easy to cross thread in those tight quarters.

 

[Chief Master Sergeant]

Try the tap. Why pull an intake manifold if you don't have to.
It's the curse of aluminum.
This is exactly why I don't like aluminum heads on Broncos. Header bolts are too easy to cross thread in those tight quarters.

That’s one big ass tap. Any clue what size it might be?


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[Chief Master Sergeant]

The explorer intake is better. I wouldn't spend the time repairing a mustang intake.

Guess I can go hunt the pick and pull for an upper.


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[blubuckaroo]

That’s one big ass tap. Any clue what size it might be?


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1/2"-14 pipe tap.

 

[bronkenn]

That's probably a 1/2 npt thread size. Pretty easy to chase those threads. That's assuming it is the same as the original style intakes.

 

[blubuckaroo]

Just clean up the threads Don't make the threads any deeper.
This is one of the only times I would recommend teflon tape. Use enough to build the threads up on the nipple to fit tight. But use pipe dope too over the top of the Teflon tape.

 

[Rustytruck]

Use loctite pipe thread sealant. Or jbweld but you will need to use a propane torch to remove it.

 

[DirtDonk]

Is it a stainless hose fitting? Not that I've ever seen a pipe-thread have a galling issue, but could that be the case here, with stainless and aluminum?
I've only ever had issues with stainless-on-stainless, but have heard of others.

Good luck.

Paul

 

[tirewater]

Harbor Freight has a pretty cheap (dubious quality) pipe tap set:

https://www.harborfreight.com/6-piece-pipe-tap-die-set-91395.html

Keep in mind that it is a *pipe* fitting with reducing radius threads. So don't tap it all the way through.

 

[Chief Master Sergeant]

Harbor Freight has a pretty cheap (dubious quality) pipe tap set:

https://www.harborfreight.com/6-piece-pipe-tap-die-set-91395.html

Keep in mind that it is a *pipe* fitting with reducing radius threads. So don't tap it all the way through.

This did the trick. Thanks everyone for the info. Cleaned the threads up nicely and appears to have sealed perfectly. I guess we'll know once we get her cranked.