Last weekend I had an alarm go off on my 2007 Baja with a 496 mag and it would die at idle. I removed the IAC valve and found that it had mechanically failed. The brass shaft and spring were gone. I put a bore scope through the intake from the rear where the IAC mounts but can't find them. Does anyone have a cross section of a stock intake? The passage way seems small will the pieces get stuck or did a cylinder already ingest them? I was able to drive it back to the boat dock and everything sounded fine above idle. Has anyone else encountered this type of failure?

Somebody wanted to give you some advice and asked me to post this to help you out.

For one he needs use the oem IAC and the OEM IAC does use a spring on the rod. All the auto store IAC ( who people think will work, they do not correctly including the junk knock offs use a spring on the rod. Merc IAC does not use a spring on the rod and Merc has their IAC made here in the USA how they wanted. Merc has the IAC made specifically for it to works per the calibration in the ecm how it operates the IAC in PWM % s correctly. anyways he had a knock off IAC installed and it blew apart. I see this alot. You can post this for him not to use those knock off IAC s with the spring on the rod. I do not care if you post it or not but if you want to help him so that does not happen again there you go. Also laugh sometimes so you can lighten up on me once and while haha. Actually u do bother me at all nor never have.

Voice to text ? Because it says OE has a spring on the rod and then says it doesn't.

I believe the OE do have the spring.

Do a search here and the Ford Motorcraft # is given. I believe It is for a 2001-2003 Ford Windstar or something like that. Supposedly the aftermarkets are an issue.

The replacement I got from BUP didn't have a spring( 2002 496MAG-HO) and duty cycle is in correct range. The one I removed did have the spring and duty cycle wasn't correct.

Mac,
I cant help with your choice of a replacement but I will say that if your luck is anything like mine I would be pulling the intake and finding the missing pieces Or at least verifying that they have gone through without any damage and are definitely gone.

You’ll see on a few threads he says to use the Ford. Then later the Merc. Maybe that’s when he started selling parts to people.

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Round table talk, if Merc’s is do good, why so many IAC issues ? Programming and tblade set up or the part (probably ford’s) itself ?

Anyone know the Ford part number and years/engine/vehicle used?

I figured this out last night that there was no spring in the OEM. This sent me on a wild goose chase because I thought my engine ate it. I crossed the Mercury part number to the Napa number. I'm at the lake this weekend so I guess we'll see what if it works.

As SB said. Ford Windstar 2001-2003 3.8L V6
Standard Motor Products AC423
Motorcraft CX1766