Help! Intake manifold won't fit!

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drewmac

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I just pulled my 67 273 Commando manifold off to replace it with a Performer. Steel intake gaskets came off with the intake. Now when I put the new manifold on with Edelbrock gaskets the damn thing sits to high. I'd have to clearance the bolt holes to get them in. I pulled off the gaskets and put the manifold on without them and it lines up. What do I do!? I know you are not supposed to use steel gaskets with aluminum heads. Does someone make a thin fiber gasket?
 
Do you have dowel pins in the china walls? If so, they have to come out for aftermarket intakes to drop down to the proper location. How about some pics?
 
It sounds like your old intake has been milled sometime before because of a possible head or block mill. Put the iron one on with no gaskets and then measure with two sets of feeler gauges on each side. Then do the same with the aluminum intake and see how much difference you have. And here is a good read for some other things to check and be aware of.
http://www.hughesengines.com/Upload/TechArticles/INTAKE_MANIFOLD_SEALINGJULY2015.pdf
 
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You need to set the new intake on without gaskets. Look and see if the bolt holes line up.

If they do, measure whatever intake gasket you are going to use (not the steel shims gaskets I hope...they are hard to seal in a bimetal application) and that is how much you mill off each side of the manifold.

You also need to mill some off the end rails of the manifold.

DO NOT slot the holes. You’ll get the bolts in, but the ports won’t line up.
 
It sounds like your old intake has been milled sometime before because of a possible head or block mill. Put the iron one on with no gaskets and then measure with two sets of feeler gauges on each side. Then do the same with the aluminum intake and see how much difference you have. And here is a good read for some other things to check and be aware of.
http://www.hughesengines.com/Upload/TechArticles/INTAKE_MANIFOLD_SEALINGJULY2015.pdf

You need to set the new intake on without gaskets. Look and see if the bolt holes line up.

If they do, measure whatever intake gasket you are going to use (not the steel shims gaskets I hope...they are hard to seal in a bimetal application) and that is how much you mill off each side of the manifold.

You also need to mill some off the end rails of the manifold.

DO NOT slot the holes. You’ll get the bolts in, but the ports won’t line up.

I had the same problem with my Edelbrock intake, but just worked at getting it solidly settled for a bit, and even pushed down on it while putting the bolts in and finally got it.
That was with standard blue Felpro Print O seals.
 
You need to set the new intake on without gaskets. Look and see if the bolt holes line up.

If they do, measure whatever intake gasket you are going to use (not the steel shims gaskets I hope...they are hard to seal in a bimetal application) and that is how much you mill off each side of the manifold.

You also need to mill some off the end rails of the manifold.

DO NOT slot the holes. You’ll get the bolts in, but the ports won’t line up.

Yes they did align with no gaskets on the Performer. Thanks for the warning on the holes.
 
It sounds like your old intake has been milled sometime before because of a possible head or block mill. Put the iron one on with no gaskets and then measure with two sets of feeler gauges on each side. Then do the same with the aluminum intake and see how much difference you have. And here is a good read for some other things to check and be aware of.
http://www.hughesengines.com/Upload/TechArticles/INTAKE_MANIFOLD_SEALINGJULY2015.pdf

Great call. I will do that and look at the article.
 
I did that exact job on my 66 Barracuda last weekend and had the same issue.
The bolts secure to the heads and they're angled. The thickness of a new gasket is the issue...you have to align it perfect and catch a few screws on both sides, but don't draw them in till you have them all caught.

When the gasket is compressed, they line up perfect.

I didn't want to disturb the timing and left the distributor in...the last bolt was a pain to get at with the throttle cable bracket in place. You could draw down all the bolts, then pull the last two to add the bracket. Ultimately, you'll need a 1/4" drive ratchet with a 9/16" socket to get that one.....if you chose to do it my "back assward way"
 
Are you sure the heads a the correct year castings? The 64-65 heads are different from the 66 & later heads. That's the first thing I would check.
 
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Are you sure the heads a the correct year castings? The 64-66 heads are different from the 67 & later heads. That's the first thing I would check.

it’s the 64/65 heads that have the different bolt angle. 66-up use the same bolt angle.
 
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If you're using the supplied cork china wall gaskets there most likely too thick. Those gaskets will keep the holes from lining up properly. I typically use them as a pattern to cut thinner gaskets from a sheet of gasket material. 65'
 
Are you sure the heads a the correct year castings? The 64-66 heads are different from the 67 & later heads. That's the first thing I would check.
Wrong! 64 and 65 heads are the odd ones. 66 and newer up to Magnum engines are the same.
 
I just pulled my 67 273 Commando manifold off to replace it with a Performer. Steel intake gaskets came off with the intake. Now when I put the new manifold on with Edelbrock gaskets the damn thing sits to high. I'd have to clearance the bolt holes to get them in. I pulled off the gaskets and put the manifold on without them and it lines up. What do I do!? I know you are not supposed to use steel gaskets with aluminum heads. Does someone make a thin fiber gasket?


Post some good photos of what you have going on and tell us what size your intake bolts are.
 
TMM, I had a couple of early 66 273's that where the heads were the same as 64-65. That's why I mentioned checking the heads.
 
TMM, I had a couple of early 66 273's that where the heads were the same as 64-65. That's why I mentioned checking the heads.
Never heard of that before, never seen it, but never say never.
 
If you remember, some times at the end a model year run whatever was left in the parts bins were used. My June 67 build date 68 Barracuda had ductile iron rockers instead of stamped steel rockers. The adjusters were at the very top & the car didn't run worth a damn, wrong pushrods. LOL Strange things happen back then & it might be that the PO swapped out the heads & intake. At the age of our cars & as many oweners as some of them have had, it's always a good idea to eliminate any of the odd possibilities.
 
Fel Pro metal gaskets are the thinnest. Surfaces need to be perfect though.
 
I did that exact job on my 66 Barracuda last weekend and had the same issue.
The bolts secure to the heads and they're angled. The thickness of a new gasket is the issue...you have to align it perfect and catch a few screws on both sides, but don't draw them in till you have them all caught.

When the gasket is compressed, they line up perfect.

I didn't want to disturb the timing and left the distributor in...the last bolt was a pain to get at with the throttle cable bracket in place. You could draw down all the bolts, then pull the last two to add the bracket. Ultimately, you'll need a 1/4" drive ratchet with a 9/16" socket to get that one.....if you chose to do it my "back assward way"

Left my dizzy in too. Great minds think alike! Pretty much been trying the "wiggle in method. Pretty close ( I even stood on the intake for a few minutes!) But it won't drop down any more (yet). I'll keep working at it. A little trim on the manifold may end up being the solution but you never know.
 
Are you sure the heads a the correct year castings? The 64-66 heads are different from the 67 & later heads. That's the first thing I would check.

Yes they are 67. No gaskets everything fits perfect. With gaskets and the manifold is just to high.
 
Yes they are 67. No gaskets everything fits perfect. With gaskets and the manifold is just to high.


That means pick the gaskets you want, measure them, and tell the shop to get the manifold flat and THEN remove the thickness of the gasket. If they just put the intake in the mill and remove the gasket thickness, it won’t be quite enough.

Don’t use end rail gaskets. Get some right stuff or similar and lay a bead on the china rails and go.

Edit: there is no such thing as a flat manifold surface. Not even on new manifolds.
 
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