What size vacuum hose is needed for this my truck did not come with this from factory?

3/16 I believe. Are you sure that it is the correct part the other lines are water hoses. My ford had a vacuum water control valve which is the one that showed. Other models use a cable to control the valve.

Can i just manually control valve if i use it on a vehicle with no vacuum?

No. There is no external linkage you could access to work this manually without vacuum. You'll need to look into much older applications, like early 70s

Anyone else hwving to replace theirs once every 6 years or so?

Yup, I have replaced that valve twice. First time about 2010. Last time 3 years ago, so the first one lasted 9 years. Hopefully this one lasts another 6 years...

I used it on 96 Ford ranger 2.3 litre. Still working great for several years now.

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