Help! I have a broken exhaust manifold stud in a 97 4.6. I thought it had just fallen out of my factory casts but its broken off in the block. Any ideas?

 

I guess the question stumped everyone! It seems that all they talk about is mufflers. #1. Is it broken off at the block? If it is then you may have to heat it up with a torch and get lucky with an easy-out. Oh and remove the manifold.
#2. If it is screwed up then you can use a heli-coil to replace the threads.

 

If it's broken off below the surface of the manifold then you'll have to remove the manifold to get at it. Removing the inner wheel well will make this task much easier.

After you remove the manifold there will hopefully be a little bit of the stud sticking out of the head. Soak the portrion that is sticking up with penetrating fluid. Then use a good pair of vise grips to unscrew the remnant of the stud using the vise grips.

Good luck.

 

Mine broke from rust. It was just below the head surface. I Iwas able to drill about 1/8" hole and tap in a square easy-out and turn with wise grip on e-out. It was clean in the head and after light soaking it came out. I replaced all on both sides. Since then Ford had bulliten to use STAINLESS steel studs. Removing inner liner helps, if you let it go too long, exhaust gas will errode AL head surface. Good luck Mark