I replaced the exhaust manifold gaskets this weekend, let me tell this is not fun. I had three studs break of in the head. One cam out fairly easy with an easy out. The other two I had to drill out and retap the threads. If it wasn't for a couple of 12" long drill bits and a Right Angle drill I don't know how I would've got this job done!

Tell me some of your Exhaust Manifold Horror story's

 

Not just gaskets, my manifold had a hole on the leading edge... Rusty Nuts(?) on mine...


Craftsman nut-out kit worked on the top 4 nuts...


Resorted to a sawz-all to get at the bottom 4... not an option if the manifold is still good...


Got it done... only 3 studs backed out, none snapped off...

 

Ouch! That really sucks.

 

WOW! Brotherhood not much left of that manifold, I'm glad I don't have to deal with salty roads. My manifolds are still in good shape. I was in the process of putting on a set of shorty headers and decided to take them of and put my stock manifolds back on. I bought the headers about 5 years ago and never got around to putting them on. Since I needed to put on some new gaskets I figured I would put on my headers, but nothing would line up just right. The tube coming from the the EGR Valve didn't line up at all and was not in the mood to modify it.

 

i was about to ask why u didn't just put headers on. haha When i put my longtubes on, my truck started out up north for most of its life so you can imagine the problems with rust. broke egr line, dipstick would not come out of the block and finally it broke off on me, and the studs where so rusted that they cam out with the bolts. I only broke one stud but was able to get it with the nut-out kit goodtimes

 

One day I'll put on a set of long tubes. I'm thinking when I have to do a engine rebuild that would be a good time to install a set. I'll probably put on a set of Pacesetter long tubes cause I don't have to deal with the salt eating up my truck down here in florida.

 

I think you'll be good with the pacesetters, i've got the 4.6 and they aren't ment for that engine at all. Ppl who have put them on the 5.4 havent had as much trouble

 

That's good to hear, I bet it's still a PITA! Performance upgrades never seem to be easy.

 

That goes without saying! But thats part of the fun in doin your own mods!! lol

 

My 02' SuperCrew failed PA inspection about a week ago because of a leaking exhaust manifold on the passenger side. It turns out that the "ticking" noise I've had for about a year was related to this exhaust leak because two (2) studs broke off on the #4 cylinder holding the exhaust manifold to the head. So, after reading some forum information about some a 2005 TSB from Ford on using new S.S. studs and nuts, I decided to replace all the studs and nuts with S.S along with new exhaust gaskets.... What a nightmare that was. First off NAPA here, which is owned by a large Ford dealership, had all the new stainless steel studs but the nuts were not so I had to order them from Totally Stainless.com. Got them and they are the M8x1.25mm serrated flange type that will not rust or come loose anytime soon. Started on the passenger side on Saturday and figure 3-4 hours of work would complete the job.... NOT! It took a lot of grinding and cutting with dremel tools, air grinders, zip wheels and such just to get the old rusted nuts and studs out. Awkward to say the least as there is not much room to maneuver with the tools because of welded frame supports for the upper 'A' arms and the starter had to be removed to access other studs and nuts underneath. Studs came out pretty easy once you got the nuts off by using two nuts jammed together and then backing them out with an air ratchet. One stud took me almost 3 hours because it broke off in the head and had to be drilled out with a right angle drill and an easy out. Passenger side-7 hrs.

Drivers side was not that bad except it was tight around the ABS braking system module and the steering shaft was in the way too. All the nuts and studs came out easier then the passenger side but still awkward and cumbersome. All new S.S. studs and nuts got a coating of copper based anti-seize compound before installing so if I have to do this again, at least they will come out easier. Drivers side 4 hrs.

My truck is nice and quit again without the exhaust leak ticking noise but I don't wish that job on anybody who needs to replace the studs and nuts for the exhaust manifolds.

 

Might as well put headers on. took me 17hrs