Intake Manifold Woes

Has anyone found a long term solution to the "gunk/carbon" that tends to build up in the 3.8 Intake? I just had the lower intake gaskets replaced and the Intake runners cleaned (only 46,000 miles). The IMRC controls had self destructed due to trying to actuate "frozen" control rods due to all the build up. One mechanic stated that they have had some success with a Ford fogging spray into the throttle body but stated that it has not helped in all cases. The car is running great now but I don't wish to spend the bucks in another 30-40,000 miles to do this again.

PS, for all of you out there with "squeaking" noises coming from the timing cover area (not belt or bearing related) the fix is a replacement fuel injection synchronizer unit (sits below the Cam position sensor).

I think most of it is just due to poor design :banghead: , but emptying a spray can of carb/intake cleaner trough the PCV line or stub on the intake (on a running van) every now & then should help quite a bit.
G/luck
Joel

Have you tried the redesigned valve cover?

For another idea take a look at this link:

http://www.miracerros.com/mustang/pcv_filter.htm

Thanks for the replies. I do have the "new" valve cover in place. I did see the filter mod the other day and may do that to my PCV system anyway as additional insurance.