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welding stock exhaust manifolds?

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Old 02-24-2011, 04:01 AM
Join Date: Jul 2009
Posts: 90
welding stock exhaust manifolds?

found two small cracks in the stock exhaust manifolds of my 2003 f150 FX4, can they be welded up? i'm just looking for a temporary fix, something to last a year or so until I sell it and get a new truck.
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Old 02-24-2011, 04:56 AM
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Join Date: Oct 2005
Location: MI
Vehicle: 1998 Ford F150 5.4L 4X4
Posts: 25,636
I don't see why not. I've never had to,- just migged exhaust myself. Yea, I don't see why couldn't, if you clean it up well.

On the other hand, Dorman sells replacements pretty cheap. I've seen them for as low as $27 on ebay and from Dorman.

Whatever you do, -replace your trans mount. That's why they snap studs @ the manifold. That exhaust damper is bolted to the mount. When the mount wears out, you get allot of vibration thru the Y. This fatigues the manifold bolts. Most likely why yours is cracked.
Windsor Built 5.4L, E40D, Transgo kit, 9.75 Rear gear, Brembo rotors, Carquest Blue's, Bilstein's, Ported & Polished Intake/TB, Denso Iridium's, Pace setter LTH's, Magnaflow HFC's, Magnaflow 20X9X2.5 HF Muffler, Type 3 19lb Injectors, Volant Intake w/Amsoil EEA191 Filter, 265/17 GY Fortera's.

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Old 02-24-2011, 05:22 AM
Join Date: Feb 2011
Posts: 52
They are cast iron, they can be welded but not very easy to do. You would need to remove them, heat in an oven and weld while still hot. You would need a "high nickel" rod if stick welding, TIG would be a better bet.

I have had some success braising manifolds, but that is a temporary cure at best.

I would get one from a JY or switch to headers.
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Old 02-24-2011, 07:02 PM
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Join Date: Oct 2009
Location: Missouri
Vehicle: 2006 Ford F250
Posts: 6,172
X2 for heads. Welding cast is very difficult, and it won't last.

FYI - I have been welding for quite a few years.
2006 F250 Lariat FX4 6.0 PSD
Performance: EGR delete, SCT tuned, 3.5" straight pipe
Other mods: Nathan Airchime K5HA locomotive horns

Nathan Airchime K5HA - short burst
Nathan Airchime K5HA - time delay
F150 Exhaust Borla true dual X pipe
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