6.4 intake manifold paperweight?

[GeauxinUp]

I was getting ready to install my 6.4 intake, and was doing one last once-over. I discovered that the brake booster port on the back of the intake is broken off flush with the manifold. Is there any fix to this, or do I just have an expensive paperweight??

 

[GeauxinUp]

Pic for reference

 

[Ken226]

I've done repairs like this before.

A few options.

The weakest: Roughen the area with coarse sandpaper, clean it thoroughly, then glue it back on with a 2 part epoxy or JB Weld.

Another option would be plastic welding. I believe the intake is made of glass reenforced nylon, so you'd need a heat gun and nylon 66 filler rod.

My favorite for this type of job is to drill and tap the hole, then use a thread-in brass hose barb. You can add some epoxy to the threads to reduce the chance of it backing out.

If you drill and tap, position the intake overhead, with the hole facing down (chips don't fall UP) and have a helper keep a shop-vac nozzle near the hole. While drilling AND tapping.
You don't want any plastic chips finding their way into the intake, and later into a cylinder.

 

[GeauxinUp]

I've done repairs like this before.

A few options.

The weakest: Roughen the area with coarse sandpaper, clean it thoroughly, then glue it back on with a 2 part epoxy or JB Weld.

Another option would be plastic welding. I believe the intake is made of glass reenforced nylon, so you'd need a heat gun and nylon 66 filler rod.

My favorite for this type of job is to drill and tap the hole, then use a thread-in brass hose barb. You can add some epoxy to the threads to reduce the chance of it backing out.

If you drill and tap, position the intake overhead, with the hole facing down (chips don't fall UP) and have a helper keep a shop-vac nozzle near the hole. While drilling AND tapping.
You don't want any plastic chips finding their way into the intake, and later into a cylinder.

I thought about drilling and tapping a barbed fitting (your 3rd option), would just make me a little nervous about it cracking since it’s so close to that corner. I wonder the depth on the backside (the flat part), if I’d have enough room (depth) to tap it there?

 

[diymirage]

If you drill and tap, position the intake overhead, with the hole facing down (chips don't fall UP) and have a helper keep a shop-vac nozzle near the hole. While drilling AND tapping.
You don't want any plastic chips finding their way into the intake, and later into a cylinder.

It sounds like the intake is off the truck, so it could get power washed before installation to make sure all chips are out

 

[Ken226]

I'm not sure. It's a judgement call. You have the part in-hand, so are in a much better position than me to decide it's probability of success.

It's a low stress application, so it it probably doesn't have to be super strong.

I bet it broke in shipping, from being bounced around in the box and not from any actual use. I'm sure 2 part epoxy would hold up fine. Especially if you supported the hose with a bracket or something, to further reduce any stress on the barb.

 

[diymirage]

I'm not too familiar with the 6.4, but logical speaking, were just looking for manifold vacuum, no?

So could we patch that hole and find a different port to tap into?

 

[Ken226]

I'm not too familiar with the 6.4, but logical speaking, were just looking for manifold vacuum, no?

So could we patch that hole and find a different port to tap into?

Yes. If there is another. I'm not very familiar with the 6.4 intake either.

 

[GeauxinUp]

I think we’re gonna be good to go fellas!! Thanks for the help and ideas. Pretty sure this is gonna work perfectly

 

[Wild one]

I think we’re gonna be good to go fellas!! Thanks for the help and ideas. Pretty sure this is gonna work perfectly

Strip the manifold down as i see the map sensor is still in it,spray it full of engine degreaser then wash the hell out of the inside and outside of it using your local coin-op carwash,then blow dry it.Odds are if it's a used manifold,it'll have a build up of oily crud inside it.Alot of times i'll prewash the inside using my old syphon wash gun and cheap gas,to loosen up the internal oily sludge build up,then do the degreaser and carwash afterwards.If you don't have a syphon wash gun,you can fill it up with gas,and then shake the hell out of it,to pre-loosen the oily build-up.No gas won't hurt it.

 

[GeauxinUp]

Strip the manifold down as i see the map sensor is still in it,spray it full of engine degreaser then wash the hell out of the inside and outside of it using your local coin-op carwash,then blow dry it.Odds are if it's a used manifold,it'll have a build up of oily crud inside it.Alot of times i'll prewash the inside using my old syphon wash gun and cheap gas,to loosen up the internal oily sludge build up,then do the degreaser and carwash afterwards.If you don't have a syphon wash gun,you can fill it up with gas,and then shake the hell out of it,to pre-loosen the oily build-up.No gas won't hurt it.

It’s used from LKQ, and it was pretty dirty. I poured some gas in there and sloshed it around best I could, then let it soak with some dawn dish soap for a few hours, occasionally hitting it with the hose until the suds started coming out the ports. Dumped it all out, then hit it with my pressure washer until I didn’t see any more suds. Gave it one more full up with water, sloshed it all around, and dumped it out again. Then I hit it with the air hose and let it dry out in the sun for a while. Didn’t really see a lot of crap come out of the inside, don’t know if that means I didn’t get it good enough, or if there wasn’t much to come out! Haha

 

[Wild one]

It’s used from LKQ, and it was pretty dirty. I poured some gas in there and sloshed it around best I could, then let it soak with some dawn dish soap for a few hours, occasionally hitting it with the hose until the suds started coming out the ports. Dumped it all out, then hit it with my pressure washer until I didn’t see any more suds. Gave it one more full up with water, sloshed it all around, and dumped it out again. Then I hit it with the air hose and let it dry out in the sun for a while. Didn’t really see a lot of crap come out of the inside, don’t know if that means I didn’t get it good enough, or if there wasn’t much to come out! Haha

You usually don't see much come out of it,but if you push a rag into it with a long screwdriver ,that'll give you an idea of how clean you got it.Usually a fill up with gas and a good shake will get most of the oily crap out of them,then a follow up with some degreaser or dish soap and a good high pressure cleaning will get the inside almost as clean as if it was new again.

 

[Wild one]

It’s used from LKQ, and it was pretty dirty. I poured some gas in there and sloshed it around best I could, then let it soak with some dawn dish soap for a few hours, occasionally hitting it with the hose until the suds started coming out the ports. Dumped it all out, then hit it with my pressure washer until I didn’t see any more suds. Gave it one more full up with water, sloshed it all around, and dumped it out again. Then I hit it with the air hose and let it dry out in the sun for a while. Didn’t really see a lot of crap come out of the inside, don’t know if that means I didn’t get it good enough, or if there wasn’t much to come out! Haha

If you're bored this guy has a couple decent video's on porting the 6.4 manifolds,he's doing it on the cars intake,but everything also applies to the truck manifolds to.

How To Port A 392 Hemi Intake manifold

I try porting an intake manifold that I bought at a local mopar swap meet and car show. #scatpack #challenger #charger #392hemi

www.youtube.com

How To Port A 392 Hemi Intake Manifold 2

Porting Intake number two with some more detailed tips for you guys.

www.youtube.com

 

[GeauxinUp]

If you're bored this guy has a couple decent video's on porting the 6.4 manifolds,he's doing it on the cars intake,but everything also applies to the truck manifolds to.

How To Port A 392 Hemi Intake manifold

I try porting an intake manifold that I bought at a local mopar swap meet and car show. #scatpack #challenger #charger #392hemi

www.youtube.com

How To Port A 392 Hemi Intake Manifold 2

Porting Intake number two with some more detailed tips for you guys.

www.youtube.com

Gonna check these out for sure. I gave up for the night…that SRV connector kicked my a$$!