It got me, too

Dropped off the Van this morning to get the recall on the door handle done, the cooling system flushed and the state inspection done when my phone rang and the service manager told me not to have the system flushed, the mechanic saw a small puddle of coolant and said that the intake gasket is leaking and the flush would make the leak worse. So far there are no overheating issues and I never had to add any coolant this past year since I had the van. Dealer says that the leak is not bad, no run-off down the engine. They quoted $630.- for the repair. I have to check if they can apply my 10% off coupon I got in the mail a few weeks ago.

Better not wait to get it done. If that coolant leaks into your crankcase, your next repair could be a rebuilt engine. $630 is about right for a dealer, and that is where I'd get it done since they have an ENORMOUS amount of experience replacing these gaskets.

the mechanic saw a small puddle of coolant and said that the intake gasket is leakingJust based on that, things sound fishy. While it very well may be leaking, a puddle wouldn't normally form unless it had been sitting for some time. The engine usually gets hot enough so that most coolant vaporizes by the time it runs down the block. Only when it's cooled down enough that liquids don't evaporate that it's evident. Now if it was a major leak, that could cause a quick puddle. But you'd also see evidence that your coolant level was going down.

How well do you trust your mechanic? Unfortunately it's not unheard of that a mechanic "finds" things wrong that aren't really.

CDRU-
I am not quite sure. Usually I am working on my vehicles myself, very seldom I'll take them to the dealer. When I picked up the van yesterday evening, the service manager told me that the leak was very small and that the coolant evaporates. I guess I need to check if the van sits for a while. The service manager said that he would honor the 10% off coupon (expires end of this month) which would bring the repair to about $570.-. I would try to do the repair myself since I have the service manuals for the van but I already have enough stuff on my plate to take care off as it is and I don't have a garage or carport either. So at the moment I am not sure what to do.
This would be the 2nd larger repair since I had to replace the rear axle before (was bent because previous owner must have had it on a roll back and when the chained it down, they used those "pretty handy" tie-down holes of the axle). Van has about 107'000 miles.

Anything else I should replace while the dealer has the intake down?
Like thermostat?
I did the plugs, wires & air filter about 8000 miles ago.

If you have any valve taps, now would be the time to have any bad lifters replaced.

Definitely new thermostat, Stant makes one of the best. In some respects I'm parinoid and if I were you I'd like to see the resulting puddle leak for myself. Also, fill the white collant reservoir tank to an exact level and keep a close eye on it and if you have a leak you will lose coolant relative to the size of the puddle and quantity of the leak. If you in fact have a leak, make sure it isn't from one of the coolant hoses or the temprature sensor.

Next, never be afraid to use those two words; "SHOW ME", ask the dealer/technician to show you *EXACTLY* where it is leaking and it should be moist if not wet. If you are fortunate enough to have a, "reputable," independent garage in your town, get a second opinion and go from there.

Radiator repair shops, (maybe air cond repair shop), have a device they screw on the radiator cap then pump up pressure on the system making it easier to find a leak anywhere. Next thing, if you have say a 15 lb radiator cap drop down to a 10 or 7 lb and see if it still leaks. Less pressure in the system, less chance of it leaking. Not a permanent fix but if it doesn't run hot it's a way to hold off the dogs until you can save enough money to get it fixed. I live close to Savannah, GA and run a 7 lb on mine in winter and it runs fine.

I drove the van to work this morning and checked the coolant level after the engine cooled (I haven't really checked too closely at home since the van is always parked on an incline and usually my wife drives it) and the reservoir is a little over 1/2" below the cold mark and I do see some moisture (not puddles).