Air intake baffle

[NewToCars]

I have a 2000 Ford Windstar SE. I took it to the shop because of slight rattling noise it makes. Noise isn't really loud, but thought I'd get it checked out. The mechanic (at a Ford dealership) says it is a broken air intake baffle (diagnosed based on sound alone, they haven't actually looked in there). I had the isolator bolt repair done in 2006, and he said this is something different but is in the manifold. Anyway, the repair is $500. The mechanic "recommends" the repair, but also said they have never seen a broken baffle cause problems later on down the road (implying the repair isn't really necessary and won't ever be). I honestly know nothing about cars, so I have no idea if this is true. So, I have come here for help. Should I get this repair done or is it really just going to be a minor noise annoyance so I don't need to do anything? I have been googling all afternoon and can't find much reference to this baffle except a passing reference here and there to it as part of the 171 and 174 code repairs (just a part you will encounter during the repair). Any help would be greatly appreciated! Thanks.

[12Ounce]

I you have no codes and can live with noise, I think it is safe to drive. It is possible to stick the pieces together with RTV, spending no parts money, and eliminate the noise. That's what I did to my '99 ... but it is a DIY fix, not "by the book".

[phil-l]

Here's what the baffle looks like on my '00:

http://good-times.webshots.com/photo...56340866tnOBqB

The baffle is in the center. The top of the upper manifold is on the left; the bottom of the upper manifold is on the right. The baffle fits between the two.

Personally, I find noises like this to be thoroughly annoying - so I'd fix it myself. But I highly doubt it would cause real problems.

[12Ounce]

Originally Posted by phil-l

The baffle is in the center. The top of the upper manifold is on the left.....

On my '99 the baffle was clipped to the upper piece. Over time these clips broke. My first repair was to RTV the baffle to the upper. I ran several thousands of miles this way. ( On latter models, the baffle was fused to the upper piece. Don't know exactly when this upgrade took place.)

Originally Posted by phil-l

.... the bottom of the upper manifold is on the right. The baffle fits between the two......

My shop manual refers to this lower piece as the intake "spacer" ... as it sits between the "upper" and the "lower" .... Just in case you ever hear/read of the "intake spacer".

After using the noted repair several thousand miles, I was in the engine again ... and changed my "fix": I broke the baffle loose from the upper and broke away all remaining pieces of the original retaining clips. I then RTV'd the baffle to the spacer (lower) ... and this fix has been most satisfying ... no noise ... and no oil dripping down on the EGR jets.

Thanks for the photo BTW.

[phil-l]

I must admit, I simply don't remember how the baffle was attached. I don't recall having problems getting it apart.

Mine has always been quiet, so I can't complain...

[Off_Timing]

IIRC, on my 2000 LX w/ 3.8L, the baffle attached to the upper half with tabs (tabs molded on the baffle). Though it's been a while since I had it out.

[12Ounce]

"Tab"s is a better word choice than my "clips". The tabs are molded in place in the plastic parts.