I did alot of checking on this and i have the same issue others have had.
Loud engine all of a sudden, sounds like a diesel.
Seems to be on drivers side only.
I looked at it, and the manifold is pretty rusted out.
Now I have read about easier solutions in case the bolts break when replacing the manifold.
No muffler shop or local mechanic wants to risk touching it and they told me i have to go to a ford service center/dealer.
I called 3 in my area and ALL of them said "alot of warping probably" will need to replace alot and drill out the bolts etc.
I personally thought an experienced ford shop would know the tricks to get out any bolts that may snap.
They quoted $600 a side minimum etc (passenger side is ok now, but hell, it will go too in the future i bet)
Anyone have any advice on how to handle this?

 

I had a local mechanic do it, luckily the job went good no studs snapped off, but it was pretty bad. All I can say is lots of PB blaster penetrant oil, soak a few times and let sit over period of 1 or 2 days before attempting removal, buy a stud remover. Youll need to put this on a lift if u plan n doing it yourself. No fun to perform this on the ground/jack stands. Buy your own manifolds, I got both for under $100, I had to buy the studs from Ford, the set for my V8 was $133 just for the studs and nuts, but they are supposedly "anti-corrosive". I think they are just copper coated. I would also replace your passenger side while your at it...I know its bad but, it may save you some money in the future. Once the studs get really bad there is no choice other than to pull the engine and retap the heads.

 

Well, i found a Ford dealership that was willing to work on it with care.
Both sides, exhaust manifolds, 4 gaskets, the stainless gasket set, and 8+ hours labor. Total quoted firm at $1,200. And yes that is with broken studs.
I told them to do it. Hopefully they will be done tomorrow.

 

My total bill for my manifolds was $215 for labor (5 hrs worth) 133 for studs and 98$ for manifolds and gaskets. $446 total :-D

 

what year is your truck cnelhybel?

 

It's a '98 xlt off road super cab.
1 year ago i replaced my starter and boy was it a bitch. at that time i noticed the massive corrosion all over the exhaust on the engine. it was real bad.

 

Jeez....... you could have bought a long tube header kit for that.

 

I know.
It was the labor that drove the cost so high. 8 studs busted flush. well i also had it inspected and oil change done. Before i took it in, there was so much corrosion, it looked like a rust coral reef. now it looks like new.
It was the first money i had to put in this truck since i got it custom ordered and shipped up from Philadelphia to me in NE PA, in late 1998. Well, i did have to spend close to $100 on a new starter last year, but installed it myself. Thats when i first noticed the nasty corrosion.

 

that job is a pain. you really have to have a mechanic you trust do this. when ford quotes a price including if they brake studs....who knows how many really broke and how much price is going up.

 

Oh man I agree.....good luck and keep a close eye on the job after ward cause that a tough job to do in the first place.....Hope they do it right.