Ford Super Duty (1999-2016) :: Broken Exhaust Manifold Bolts - Long Term Fix?
Aug 20, 2014
I've got the dreaded broken exhaust manifold studs on my 2004 F250 V10. I don't drive it much (just 50,000 miles in 10 years) and confess I've ignored the hissing for quite a while. Is there really a permanent fix for these broken studs? Or should I expect to be replacing broken studs every 2 or 3 years?
If there is a permanent fix what is it? Special studs? Special manifold? I want to keep this truck a long time and don't want to be replacing these studs every few years.
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Our F-450 with 102000 miles lost both turbos also broken exhaust manifold bolts. This truck carries tools fuel tank and sometimes skid loader on trailer. Heard lots of bad things about 6.4 liter motor now first hand experience. Asked dealer if 6500.00 bill could be reduced since so close to 100000 mile warranty and was told nothing could be done. Can not afford to sell truck now also have two other Ford F-250s newest one 2012. Is there any other approach that could be taken to get some relief from this expense.
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Bolts breaking on the exhaust manifold. If so why isn't ford doing a recall on this problem I have a F350 V10 90K miles and 3 on the top drivers side are missing not sure on the passenger side. Is this a problem with all the ford engines I have never had this problem with any other truck or car I have owned.
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Just bought a 03, the seller showed me a exhaust leak. I found a bolt broken off, flush with the head. Looked at the passenger side when I got home, that side leaks too, and found one broken off bolt there too. Question, are these easy to do? As in, I have extracted broken bolts before, but they where on my V10 and I could just weld nuts to them and they came right out.
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I got a 08 ford f450 sd in the shop with a cracked abd broken bolt in the driver's side exhaust manifold, any tips tricks on getting it out,I have everything loose but I can't for the life of me get the egr cooler out of the way to access the top bolts to the manifold so I can replace the manifold, or a link to a service manual would be great.
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I only live 6 miles from work and I've been getting a lot of condensation gunk building up inside the filler cap and around the neck. Is there going to be any long term damage from this? Here is a picture of what I'm getting.
I know it's not coolant because I'm not loosing any and the oil on the dipstick is clean.
Since it got cold I've been taking another route to work that gets me up to 9 miles one way. Also, twice a week I take the long way home that has the engine running for a half hour but I'm still getting build up. In the winter I'm on call a lot and rarely go far from home so taking a two hour trip to really heat things up is probably not going to happen.
ETA. I change my oil every 3000 miles if that makes a difference.
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I have a 97 Expedition with the 5.4 engine and 160k miles. Recently while having other work done I was told that I had an exhaust manifold leak due to broken rusted bolts.
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My wife's 97 f150 4x4 had an exhaust leak on the passenger side. 7 out of the 8 bolts holding the manifold on are snapped off. 4 of them are snapped off 1/8" below the top of the hole on the cylinder head . I am I unable to get a drill in to drill these out. The other 3 I've tried welding a nut on these but they won't budge and I wring the nuts off. If I have to pull the head(something I don't want to do)can I just pull that 1 head or do I have to tear the intake and everything off?
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I have a 97 f350 crew cab xl stock everything. 351 windsor in it I do believe. as of right now He is broken down pulled apart in my garage. Due to a much requested headgasket replacement. In any event long story short I got him all apart to discover that there was someone in it before me & had broken the infamous exhaust manifold bolts (5) and two of the lower intake bolts, (of course I've tried the correct route in removing these broken bolts/studs but again the year of the truck (1997) & its bone stock no way their moving...
So of course I tried the next best thing (on a budget) which is to drill them out, but I went to far into the exhaust manifold bolt holes, And now I believe that I've ruined the heads is this so? If so who knows where i can get a decent set of bolt on heads ready to go. yes this is my daily driver & since He's been down I've been going deeper in dept.
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My '08 S.D. (5.4) has a cracked exhaust manifold, which I've heard is fairly common. Crappy Ford design. The local dealer has them in stock (imagine that, just like the 'non-bad' coil caps from some years ago, that they were instructed by Ford to keep at least 10 on stock at all times) for the passenger and driver's side. What are the part numbers?
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The exhaust leak is not too horrible, but, enough that I need to address it soon. Only on the driver's side; (today).
I'm planning on having a lot of PB blaster on hand, torch, broken stud removers, screw/stud extractors (easy outs), ...a hammer. Maybe a few cold Budweisers
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About to do the exhaust manifold gaskets on my 03 f250.
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I've got a 2006 F250 5.4l. Recently Ive had an issue when I am driving, usually when the engine is at 3k+ RPMs, where the engine will lose power and the cel with blink. Usually it only takes a few seconds for the blinking to stop and the engine continues as normal. Now, I know that at least one of my exhaust manifolds are leaking.
Could it be that the engine is not receiving enough back pressure and that is causing it to lose power? I had a similar issue last year, basically the same symptoms, and it turned out that I had two cylinders misfiring. I replaced the coil packs and that fixed it. This time there are no codes referring to a cylinder misfire. There is a code for EVAP leak (I think), but I was told it was nothing to worry about.
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is there a set of headers for my 2008 f250 5.4 rwd that will install somewhat easily without me throwing tools across the garage? I see a lot more options for the older trucks. I have a pretty annoying exhaust manifold leak and I figure I might as well throw some headers on if im gonna be in there. I really want to go for sound rather than power. I think I saw a set by flowmaster that looked decent.
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2003 F350 short bed 6.8L V10---On start up a slight tap sound, almost like a cranky lifter, but it is an exhaust manifold leak. At the bolts, I am not sure. This has been this way for 5 years, no better no worse. After I run about 2 to 3 minutes it seals itself. Not a hint of noise. Due to heat, something is expanding to seal it (aluminum).
At my annual PA. State Safety Inspection the Tech says 'that has to be corrected if it worsens', but It does not fail inspection. This puzzles me.
How is the call made for correction. A flip of the coin, a guess and is it serious enough to fail inspection. Is this normal with the 6.8L or V10s. I know the cost involved for a fix is big league, but can it be justified. TRUCK RUNS GREAT !---
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I have an 03 F250, 5.4, 4x4, with aprox. 130k miles. I recently had my exhaust manifolds replaced because 1 literally cracked in half. Ever since the replacement, I'm getting worse gas mileage! Im only getting aprox. 250 miles to a tank when before it was well over 325 (highway)...
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Should I attempt to replace the passenger side manifold with what I can get from Napa. I would rather pay 100 bucks for everything and do it myself. But, Im concerned about replacing the studs. From what I have read the studs seam to be the problems for most leaks on these vehicles. I have torque equip. and other tools to do the job. Just want others opinions about this project. How hard really is it? 1999 5.4L F250 SDuty....
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I have an exhaust leak between the manifold and turbo ( in the flex part of the pipe) on my 2008 6.4 f250 would this create rough idle when at operating temp?
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I have a 2005 f250 5.4 no mods. its got 120k and needs a wake up. the passengers side exhaust manifold is leaking to the point of fixing and would like to get some input before the big purchase. my question is, headers or new manifold, and what brands is preferred for both I really don't prefer one or the other i just want the best fix really. Changing coil pack and getting more performance out of them and if so what brand. I would like a boost in lower end acceleration and throttle response, like a programmer or such. and if so what brand once again.
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I have a leak at the driver side exhaust manifold. Its a little tough getting at it to tell if its a lose bolt, crack or bad gasket. What would be the best way to get at this area? Should i remove the tire and wheel well or is their a better way. If i can get at it i may replace the manifold all together.
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Whats the best way to get at the driver side exhaust manifold? I have a leak and its tough to get at. Should I remove the tire and inner wheel well?
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