I have my intake manifold off and found that the intake manifold runner control metal rod and the butterflies themselves are in really good shape. The manifold was replaced in 2012 so it is only about 8 years old. So I was considering putting everything back in as it was. However when I pulled the rod and the flaps with their carriers out, I started looking for the bushings that sit between each runner and help hold/support the rod. From some videos I have seen, I think these bushings are supposed to be between #1 / #2 and between #3 / #4. However mine only had a bushing between #1 / #2. This is an image of the bushing I am referring too:



So for anyone that has worked on these, I was wondering:

1. did you just have the one bushing or did you have 2 or 3? My intake was purchased new from Ford in 2012 and so I know they weren't removed by anyone else. I guess it is possible I lost it when I was taking this apart, but that isn't very likely since it took a little effort to remove the one between #1 and #2. Also I was looking for these and expected them to be there and never saw anything.

2. Since I only have the one bushing and I think 2 may be needed, I am thinking of removing the butterfly flaps. Should I remove the rod and the flaps and just leave the holes between the runners where the rod passed, or should I just remove the flaps and put the rod back in? The rod wouldn't really seal between the runners with the flap removed though, since the rod passes tightly through the butterfly flaps (circled in red), but it would reduce the opening size a bit.

 

I've seen people leave the holes between the runners open and also seen people seal them up with epoxy. But I was wondering if I could get a piece of aluminum rod of the appropriate length and fit in there? I could either get a rod slightly smaller and put a bit of high temp silicone on it so it wouldn't move and make noise, or try to get something that is a fairly tight fit. The flapper holders would eliminate any chance that the steel rod would come out. It would basically be inserted where the bushing in the picture goes.

 

I ended up purchasing the 7/16 aluminum rod. For the longer middle section I had to turn down the rod by about 10-15 thousands to make it fit. Then on the other two it was under sized by 5-10 thousands so I made one section of the rod slightly oval by hammering on opposing sides to make it a snug fit. Sure it won't be 100% air tight between the runners, but with the rod and flaps installed it is even less so. After a day of use there seems to be no negative to doing this. I will post back if I have any longer term consequences.

 

How has truck been running with flapper delete? I am contemplating deleting mine as well.

 

How's it running now with the flaps removed? Any issues?