Well, I finally got the Ford 'optional' broken rear cylinder manifold stud(s) upgrade!!!

Actually, one broken stud on each side! On the Drivers side, it's the lower stud and on the passenger side it's the upper one. The drivers side still has part of the stud beyond the head, the pass side is broken off inside the head.... Why are those studs and nuts some damn small!!!!!

Now, the question of what to do? Here are some pros and cons I've come up with..... Let me know if you have some to add or swap around!

Doing the job myself.....

Pros:

*I've got a garage and tools.... (Know how to use most of them too! )
*Save a ton of $$ on shop labor.
*Satisfaction of doing the job myself.
*What tools I don't have, I'll have to get.... (I like that.... )

Cons:

*It looks like it's going to be a PITA to get those manifolds off ! The rest of the stud bolts look like they are welded tight with rust and I'll probably break off more studs just taking them off.
*Just to remove the pipes from the manifolds looks like a days job all by itself!
*Will probably take several days to do and my truck is a daily driver.
*I suspect I'll need a good day just to let the bolts soak in some penatrating oil before I even begin!

Have a shop do the job....

Pros:

*Drop truck off, pick truck up when it's done.
*Someone elses knuckles will get busted and not mine.
*If it ain't right, I can take it back.

Cons:

*$$$$$$$$$$$$$$$$$$.
*It will probably be in the shop for several days. Probably need to get a rental car.
*Will only be able to get worked on during the week.
*Someone else will have my truck for several days.
*If it ain't right, having to take it back.

The main problem is I'm lazy and a cheap a$$!! I don't mind doing 'minor' fixes on the truck. Usually only the kind that takes a couple of hours at most. Changing the spark plugs have been the most I've really been willing to do so far... I've replace the U joints, rear axle seals, brake jobs, change the oil..... All easy stuff. I know I'm capable of doing the exhaust manifolds and all, but then the "lazy" part keeps nagging me when I look at those rusted things each time....

Then I'm all set to call someone up and have it done.... Now the Cheap A$$ comes in..... Man, I know it'll cost a grand or more for just the labor alone! (well, I don't KNOW that, I'm only guessing at this point....). I'll need to get a rental car because I know it'll take a week in the shop! More $$$.

I know this is my problem, but just wanted to rant a little about it and if I can pick up a suggestion or advice along the way, that's even better!

Thanks for hanging with me if you've gotten this far in the post!!

Mitch

 

Well, I've done some checking around and the dealer would want to "remove the head" on the stud that's broken below the surface...... Whatever...... Needless to say, I know it does not need to go that route.....

Checked at my favorite exhaust shop and said the whole job could be done for under a grand, depending on what the new studs cost and how much trouble the rest are to take out.

Oh, I would have all the studs replaced while it was apart anyway. No sense spending all that time and effort to remove the manifolds and not at least replace the others, right?? Been toying with the idea of headers too, but my cheap a$$ side kicks in when I think of that! ha, ha!!

Mitch

 

Holy Cr@p!! Just called on the stud/nut prices....... Ford wants $6.90 per stud and $2.01 per nut!!! Lets see, that's going to be $142.56 + tax for a whole set.....

And the things just break and rust up to no end!!

I've now figured I can do just one side at a time over a weekend, so that will help with the vehicle use, but still........ Guess I should just suck it up and do what I know is the right thing to do..... Sell, it and get a Dodge!! ha, ha...... JUST KIDDING!!!

Mitch

 

Holy Cr@p!! Just called on the stud/nut prices....... Ford wants $6.90 per stud and $2.01 per nut!!! Lets see, that's going to be $142.56 + tax for a whole set.....


try arp fasteners

good stuff and for the $$$$ better than stock

...zap!

 

how ya doing?
i just found 2 broken studs on the pass. side . they didnt break flush with the head but the rest of them look very rusty and will probley break to.
did you fix your self or take it to the shop and how much

 

Mitch,
Sorry to hear of your misfortune.

Get the headers! While you have the manifolds off, get the headers!

Curt

 

took my truck to ford dealer they have a new stronger stud set for 4.6-5.4
exh. man.

 

Well, I've not done a damn thing yet! The way I figure it, the more that snap off on their own, the less I have to remove!

It's still making the noise when it's cold, but when it heats up, it's still quiet.... Once it starts sounding like a Chevy all the time is when I'll end up doing the job.....

Been thinking about the headers too... If I can find a set for under $400 I'll probably go that route too.

Thanks for the support guys!

Mitch

 

i noticed that had an exaust leal coming from my passenger side manifold also. both studs closest to the firewall were sheared off. After getting the manifold off I think the problem was the gasket was installed at the factory improperly as it was pinched and the holes were not lined up. i purchased new studs and nuts at a hardware store, and replased the gaskets, and now it is quiet again no more ticking. I went to the ford dealer and got the deminsions of the stud and the nut , took them to the hardware store and they hooked me up alot cheaper than the dealer. Total cost for the fix was $8 for the gaskets, $10 for the studs and nuts, and about 5 hours of my time.

 

This is a bunch of crap. I just found one on the passengers side of my truck & i have a nice exhaust leak. As far as i'm concerned this is a Ford problem & they should fix it. There is absolutely no reason for an exhaust stud or bolt to just snap off. I'm going to contact Ford & see what they are willing to do about this.

 

They will offer to fix it for you..... But, unless your truck is still within it's warranty period, it'll be your nickel.....

Mine went about 6 months ago with about 135k miles on it.... Ford offered to do it for around 2 grand..... Said they would have to pull the engine for the broken stud that's below the surface.... Whatever.....

I'll do it myself when I get my lazy a$$ into the mood! Still being a cheap a$$ is keeping me from the header part...

Mitch

 

My mechanic (not dealer) quoated me $750.
That was manifolds/studs/gaskets/manifold to egr tube, and his labor.

I'm going for it soon. I have new front o2's to put in at the same time.
I might put in a new egr valve for the he// of it. Truck has 93k.

 

I'm going into the dealer tomorrow for them to look at it. My truck only has 44,000 miles on it. Ehaust manifold studs or bolts should not just break off for no reason.

 

I have similar problem except the bolts on the flange at the end of the manifold that bolt to the collector have rotted in half. I had to drill them out from underneath the truck with a long drill bit extension, what a pain in the a$$. Took the truck to three different shops and they all quoted me big bucks to fix, went to Lowes and bought a $15 bit extension and did it myself. I dread having to change the manifolds, the bolts are rusted something fierce, not going to be pretty.

 

Okay I just replaced the exhaust manifold gasket on my truck passenger side only, for now...

Both rear studs were broke off at the manifold flange so i reluctantly tried the others well after turning them pretty hard (almost too the point where they would twist off in the head) I got all the front six studs out,they came out of the head with the nuts.

The threads on the studs were clean when they came out no corrosion at all.

Got the manifold off could not get back two out, I screwed on a 5/16 nut and welded it to the studs bottom one luckily came out.

Top one broke off just about even with the head and my heart sank....after about two hours of ****ing around got it out, had to drill and remove with a ez out kit GET A GOOD ONE! SNAP ON!!!!!!

Anyways replaced with bolts and lockwashers (lockwashers to keep bolt from rusting to manifold) from tractor supply, sounds great now...Good luck to anyone who does this!

Cost me $9.00 for gaskets and $3.85 for bolts (M8 x 1.25 MM)

TIPS : Remove inner fender well cut off the push pins and replace later

As stated earlier get a real good extractor kit this is one time not to cheap out

Replace junk wimpy FORD studs with bolts and lockwashers

put never seize on the bolts your screwing back in the heads

Replace nuts on two flange studs with new ones while your screwing around...