Ford F-150 (2004-2008) :: Manifold Exhaust Leak - Rusted Bolts


May 2, 2012

Truck has 107 thousand miles; had to take it in for an manifold exhaust leak. Mechanic said bolts are so rusted they break.

1) was there ever a ALERT from ford about these bolt's?
2) Thought i read ford had stainless bolts for this problem...

I've had F150's only since the mid 70's and this 04 has cost me more in repairs than ANY previous F150..

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Ford F-150 (2004-2008) :: Exhaust Manifold Leak On Passenger Side

2004 SCrew, FX4, 5.4 ... I had the dreaded exhaust manifold leak on the passenger side. After reading the horror stories of this repair and living in the rust belt I decided against fixing it myself. I took it to a local repair shop to have done. Initially the mechanic could see that the front 2 studs were snapped off (before even trying to remove them).

After a full day of fighting the studs (engine loose & lifted up) everything is out but the front 2 studs. the top one has about 1/2" exposed, but it is frozen in place (penetrate on it overnight). The biggest problem is the bottom stud. it is broken off about 1/8" below the surface of the head. The guy doesnt have a small enough right angle drill to get between the frame & head to attempt to drill it out. I will gladly go buy a drill for him to do this, as it will likely save me money if it will work to drill out the stud.

Need to get the 2 studs out, particularly the bottom one, or what right angle drill may fit in there?

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[URL]....

It is the "higher" of the sounds. The lower pulsing/whooshing is just regular engine noise. You can hear the regular engine noise as the camera pans to the back of the car.

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My truck just started running really loud when it's cold and the leak goes away when it warms up to operating temperature.I did a little bit of investigating and I have found where the leak is coming from at the end of the exhaust manifold where the donut gasket meets the catalytic converters. It appears that the bolts rotted that hold the system together at the gasket. What should I do to repair this? I don't really want to replace the whole manifold because I know I'll break a stud off in the engine because everything is pretty rusty down there. I even took some pictures of the problem....

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2005 Supercrew and my passenger side exhaust manifold was leaking. Son of a mother duck that was a joke to get removed. Front two studs broke off about 1/4" below the surface. Manifold is not cracked but putting a straight edge across it's out of plane at least a quarter inch.

Had planned on the dorman manifold but read some poor reviews about it cracking in less than a year and being warped out of the box. There is an ATP manifold with very few reviews but all good. Or just bite the bullet and do shorty headers? The driver's side looks a lot easier to access.

These trucks really weren't designed to be worked on after assembly were they? I had to invent new cuss words. Looks like Ford manifold is disco'd...

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I searched this site and youtube but didn't find any other posts. Lots of problems with older trucks with composite manifolds but nothing for this one. It looks like a part of the bottom of the manifold is plastic but the entire top and where it is leaking is all aluminum.

It seems odd that this would start in the winter time just driving back and forth to work (no load). And, yes the antifreeze is good. Just wondering if this is a known issue with this truck. Is it just a matter of replacing the gaskets or is there some other flaw I should be concerned about?

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Ford F-150 - 1997-2003 :: Possible Manifold Leak In Exhaust

So I think I have possible manifold leak in my exhaust and its because when the engine is super cold, and I do have a straight pipe, but it sounds like a tractor... until it warms up after few minutes, it goes away.

My exhaust manifolds are rusted to crap and stuff is falling off, paint or whatever there was on them.

Now I've looked at bunch of videos on UT to get a better understanding since everyone says the nuts and studs are hard to remove or snap.

Now my question to anyone who's done this in their garage; I've seen bunch of videos where the stud snaps flush, then he takes a nut, puts it over the hole, holds it up with needle pliers and uses a MIG to start welding it... stud to nut... then puts a wrench and off it goes.

Now, I'm not a pro welder or anything so is it possible to by accident weld the stud, nut into the head and then never ever be able to undo or take either one out?? or is the head or whatever made from different material that won't get welded to the nut or the stud??

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