Its official the 2valve pi manifold has ceased production.

[RAU03MACH]

switching to a 4v would be better
those parts are long gone

 

[96blak54]

https://fordauthority.com/2024/07/brand-new-2001-2004-ford-mustang-gt-intake-manifold-debuts/

Latest news from Ford. Not like we all dont already know this

 

[96blak54]

Some interesting info from the article

" This production, composite intake manifold is the same exact piece used on the 2001-2004 Ford Mustang GT equipped with the SOHC, two-valve, naturally-aspirated 4.6L V8, too. However, it’s manufactured on brand new tooling, interestingly enough"

UHM.......no.....no its not.

 

[07GtS197]

The thing is Ford will still make a lot of money on these just because it’s an “oem” part. I’m surprised another company hasn’t stepped up with a design closer to the stock intake. It’s a shame really.

 

[Mustang5L5]

EDIT: combined below

 

[Mustang5L5]

Some more pics coming out. Does look like it's a revised Dorman. Some improvements have been made. Replacable heater core hose nipple, brass inserts for the fuel rail bolts and COPS. I also have not seen any reference to this new intake shipping with a alternator bracket, so it looks like it was designed to retain the original Mustang style bracket.

It does appear this intake uses integrated gaskets, just like Dormans do.

Regardless of if Dorman is the manufacturer, or someone else, it doesn't change the fact that this new intake is NOT the same as the previous version which featured the deep plunging plenum, so it will suffer the same HP loss.

Again, right now i'm assuming this is a dorman due to the runner design. Will need more info before we can really confirm.

 

[96blak54]

Yea just looking at the runner shape and turns, how the air will move about just doesnt come close to the original.

 

[Mustang5L5]

So i wanted to try and confirm this is a Dorman, or at least a hybrid Dorman. SInce i had the one I pulled off my car, i decided to give it a quick look.

So first, here's a Amazon link to a Dorman intake for a 99-04 GT. The Dorman 615-175

https://www.amazon.com/Dorman-615-175-Manifold-Lincoln-Mercury/dp/B000CIXMIC

I have one of these, so lets look at some of the features up close and in person. ALL of these photos are the Dorman 615-175

First, this particular logo on runner #5, in addition to torque info on runner #6 and notably the bolt torque sequence scattered around the intake



Opposite side features the "MADE IN USA" on runner 1, and gasket info on #2


On runner #4 is this noticable feature.


Finally, part number on the bottom





Now, what's important to note is the Dorman intake is sold under other brands as well. Either licenced and reboxed, or perhaps some china knockoffs. No wait to comfirm if the latter, but if you look around and compare the above features, you'll see they match.

Here is an OPR branded intake, which is a dorman. Look at the photos, especially the logo on runner #5. Same as above.

Mustang Replacement PI Intake Manifold with Gasket Set (99-04 Mustang GT) - Free Shipping

FREE SHIPPING! OEM Style Replacement. If the stock intake on your 1999-2004 GT Mustang is cracked and causing you issues, replace it with a brand new direct fit

www.americanmuscle.com

And here is one of the no-name intakes. Possible rebox, or ripped off copy. Hard to say. But look at the features. A lot of the mold markings are wiped, but the torque sequence is present on the runners. I think this is a Dorman copy

Intake Manifold for 2001-2011 Ford Mustang Upgraded Design | eBay

Intake Manifold. Upgraded Design. NOTE: Fits models with 4.6L engines ONLY. Match reference numbers from the Item specifics section above. Visually compare the part you are replacing with our pictures.

www.ebay.com

 

[Mustang5L5]

Now, here is the Dorman compared to an OEM 01-04 intake manifold made the traditional way. You can clearly see the difference in runner design.

Dorman (same intake as above) on the right. Not shown is the height difference due to the deep plunging plenum on the original (left) intake.

 

[Mustang5L5]

Now to compare the new Ford Racing intake and why I think it's a revised/updated Dorman-made product.

4.6L 2V PERFORMANCE IMPROVEMENT INTAKE MANIFOLD

4.6L 2V PERFORMANCE IMPROVEMENT INTAKE MANIFOLD|Ford Performance Parts

performanceparts.ford.com

Found a pic I could blow up off ebay



There are differences, but there are some features which are distinct. First off, it's a distinct "spider" pattern of runners which Dorman is known for. But there are changes from the above intake. The internal support ribbing is different compared to the dorman intake 1 post up. But if you study the plastic mold, there are similarities.

Other difference, as mentioned, the fuel rail and COP bolt holes are brass inserts.

Similar features to the Dorman?
- Made in USA on runner 1 (different style)
- Torque sequence info on runner #2. It's almost word for word exact. They rearranged the sentences slightly
- "dent" on runner #4

Here's the new Ford intake


ANd heres the dorman. Perhaps this is a required feature for both intakes, so not a smoking gun here

 

[Mustang5L5]

Separate post for the stamped torque sequence.

Dorman Intake



And now the new Ford Intake (best angle i could get)


But compare the wording. The order of phrases is slightly rearranged however.

 

[Mustang5L5]

The underside plenums are slightly different. However, i have a photo showing the plenum depth is still short.


But here's the underside of the new Ford intake. No Dorman part number here. The actual lower plenum does appear molded slightly different. Does look a little bigger. Will need a better pic.





VS a real Dorman intake. Slightly different shape.





But here's a side by side of the new Ford intake and the original OE PI intake.

 

[Mustang5L5]

Finally gaskets. The above pics clearly show impregnated rubber gaskers on the intake, but this is interesting on Ford site




It states a gasket set is required and gives a part number

But if you search the P/N, it's a different gasket pair than what was used on the Mustang. So curious to see how this actually installs. Looking for a pic of the full kit as we speak.

 

[Mustang5L5]

Anyway, clearly we can see this intake is not exactly the same as the Dorman 615-175 intake. There are enough differences that it's another intake altogether. However, comparing them, there is evidence it may be a Dorman-made variant that Ford had revised for some reasons. The smoking gun will be if a 2025-later produced Dorman kit starts to be delivered the same way. I'd imagine Dorman would try to keep costs down, so why make two intakes for the same application, especially when they can increase volume on the new one to bring down average cost, and sell it cheaper. Makes sense unless Ford put some sort of restriction on them.

Either way, i have no way to say 100% without a doubt it's a dorman. While I suspect it, there's no way to confirm it at this time.

Folks are starting to received kits that were on backorder. Some are disappointed it's a revised intake. WOuld be curious to see LMR do a dyno on this.

Trying to find a pic of the full kit and/or install instructions.

 

[96blak54]

I will definitely be on the look out for a dyno comparison. And who knows, maybe this design has a similar comparison performance wise. You know the ford npi and pi intake "look" similar to the untrained eye.

Me seeing production of intake manifolds for 5 years, I see differences in the injection process that doesnt match the dorman, so there is hope for a better performer.

 

[Mustang5L5]

Yeah, For now i'd hesitate to say "It's a dorman" and leave it at that. It's a different intake, but its similar to the Dorman in terms of runner overall design.

Will need to wait for installs and perhaps a dyno comparison.

 

[Mustang5L5]

More pics of some of the other parts that come with the kit.





Looks like a dyno is coming….

 

[96blak54]

Yea, the new pi intake is no where near the same as the dorman. Total different manifold. Knowing the tooling associated to assemble the multiple shells of this type of manifold, no other "visual appearing" type plastic shell will fit into the die tooling associated with welding the shells together. The tooling is literally specific to the compont. Its a negative copy of the manifold component being welded and roughly 10,000lbs. And can be multiple dies depending on how many shells the manifold is made up. I cant see a simple "its the same as a dorman" copy. This manifold may appear like a dorman, but its miles apart in design.

Ill admit....im sort of hopeful now. Maybe this new design might be a major surprise! Gotta keep in mind when the pi intake was designed. If it showed up in 99, it was engineered and designed at minimum 2years before. So 1997 to 2022...15years of manifold design knowledge gained, im hopeful we will see a surprise.

 

[Mustang5L5]

I really hope the dyno that LMR does is fair and impartial. That’s all I ask.

 

[96blak54]

Dang this new intake is blowing up all the 2v FB pages. Crazy

Reading the comments and the idiocy gets to me tho. Im glad this forum is here