I was working on a friends 2003 Ranger 4.0 intake manifold removal to replace the PCM sensor located directly under the throttle body. There were two sensors mounter behind the thermostat housing. The one toward the passenger side is for the temperature gauge and the sensor towards the driver's side is for the PCM (computer module). The PCM sensor can't be replaced without removing the intake manifold due to no clearance to remove it. When I went to the auto parts store and requested both the temp sensor and PCM sensor he returned with only the temperature sensor. I opened the box and noticed it was the PCM sensor and not the temperature sensor. The counter person said the sensor he brought out was listed for the temp and didn't show the PCM sensor in his stock.as a part. I looked at the picture on his computer and it was the PCM sensor and not the temp sensor. I got on-line for this store and found the temp sensor and gave him the part number and low and behold it showed he did have temp sensor in stock under that part number I gave him. The counter person retrieved the sensor and it was indeed the temp sensor which originally didn't show up on their system. The counter person gave no reason as to why it didn't show up as in stock as a temp sensor for a 4.0 2003 Ranger. Makes me wonder how many customers got the wrong sensor. The sensors will interchange as they are both held in place with a clip but have a different electrical plug-in cap. Both are two pin and can be forced on but notice each sensor has a locating slot which matches the the correct sensor. One is slotted in the middle and the other is off-set. Finally the bolt issue. After replacing the sensors and thermostat I cleaned the intake manifold surfaces and replaced the six intake gasket seals. The eight intake bolts are TORX T-27 head and are part of the intake bolt assembly consisting of a 6 X 1.0 - 50mm bolt with a metal sleeve and rubber mounting grommet. The bolt is peened in on the tube to create a captive bolt which remains in the sleeve when removed. The rubber grommet creates an insulator and centering device for the metal tube. I looked on-line for the intake manifold torque specs and consistently found the range of 180 - 216 in-lb (Inch Pounds) using a three-step sequence. Well I broke a bolt and then another one. I could find a correct replacement available. I ended up removing the sleeve by using a small sock tapping upward. Only the rubber grommet is actually holding in place. I then used a punch and removed the broken bolt. The peen marks are the only to hold the bolt in as a captive measure only. I purchased two 6 x1.0 -50mm hex head flange bolts with a 10mm hex socket head. I measured the metal tube and found the tube was exactly the same height required to provide solid support from the upper intake manifold to the threaded female inserts in the cylinder heads. I imagine if you can find flange bolts a bolt washer combo would suffice. Now for the kicker, I got a copy (from local library) of the Ford factory service manual for a 2003 Ford Ranger. I went to the section 'repairing intake manual while in vehicle'. I was shocked to to the torque value for the eight upper intake hold-down bolts were 89 in-lb (Inch Pounds). That correct 89 in-lb while all this online crap was saying 180-215 in-lb. No wonder the bolts are breaking. Installed new bolts into the sleeve / grommet and assembled. Torqued to 89 in-lb for the eight upper intake bolts and reassembled all other components. Filled with proper coolant and bled the cooling system. Started up and brought up to temperature. Intake vacuum normal, no leaks. I'll check and re-torque in a month but to tell the truth I probably won't. Lessons learned, Know your sources, verify correct parts and most of all use common sense. Have a great day and God Bless.

 

Good write up; sounds familiar.
I've found the people at the local PartsCounter (dealership or otherwise) are generally very friendly+helpful,
but most don't really know much about your vehicle; expected as they deal with several hundred makes\models\customers each day.
Half the time they bring out wrong parts; they're trained to read computer screens & sell parts as fast as possible.
Best to confirm the part numbers you need from 3 or more sources, or even better the actual number off the old part if possible.

Interesting though on my similar 2001 V6~4.0L~SOHC, am able to get those 2 TempSensors (Gauge & PCM)
removed+replaced by removing SerpBelt+IdlerPulley+ThrottleBody without removing IntakeManifold; tight but do-able.
Strongly recommend replacing junk Plastic ThermoStatHousing with Aluminum version, if not done already.
While you're in there is a good time to consider replacing left OilPressurized TimingTensioner as well.
For more info click here https://2001fordexplorersporttrac.fa...ant_ThermoStat

Also, here's a good Torq spec listing for the V6~4.0~SOHC (note 89LbIn for IntakeManifold bolts):
https://web.archive.org/web/20200529...ations.406687/

 

Thanks for the tips and photos, very helpful. I wanted to add to my previous post. The intake was removed to allow for the removal of the critter nest, probably chipmunks or squirrels, that brought in twigs and grass into the V area under the intake manifold. The area under the upper intake provided a nice warm area and protected from rain / snow and wind. It also allowed me to remove dirt, grease and oil that accumulated for almost 20 years. I told the owner to maybe consider a pest treatment for that area. It's really inaccessible and very hard to just vacuum or blow with compressed air alone. Thanks again for your input.

Critter Nest




New Upper Intake Seals Installed

 

That was a nasty mess.
Got chipmunks around my place, will do that if vehicles left outside,
but won't get to 'em in the garage.

 

Just checking back on the follow-up for the Upper Intake Bolt issue. Rechecked torque 89 inch pounds Good. No vacuum leaks, runs great. Problem solved