leaking exhaust manifold
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Senior Member
Joined: Mar 2007
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From: NJ
leaking exhaust manifold
truck is a 2000 f150 5.4L
for the past few months i have had a small exhaust leak coming from the right side manifold, i took a look at it and noticed the rear bolt looks like it has rotted and broken off. i talked to a mechanic who said that there is a chance that the manifold is now warped and needs to be replaced or machined. and then i talked to a second mechanic who said to pull the manifold off replace the gasket and put it back on with new bolts. whats your guys opinion on this ? and how hard of a job is it to get at the manifold, has anyone on here done this job before ? looks like a little bit of a challenge just to get to it.
thanks for any help/advice
for the past few months i have had a small exhaust leak coming from the right side manifold, i took a look at it and noticed the rear bolt looks like it has rotted and broken off. i talked to a mechanic who said that there is a chance that the manifold is now warped and needs to be replaced or machined. and then i talked to a second mechanic who said to pull the manifold off replace the gasket and put it back on with new bolts. whats your guys opinion on this ? and how hard of a job is it to get at the manifold, has anyone on here done this job before ? looks like a little bit of a challenge just to get to it.
thanks for any help/advice
If it broke the bolts you may need to drill / easy out the studs/bolts (not sure what a 2000 has my 04 has studs). This will cause alot of work and possibly need to pull the head off in order to drill. I've done a few manifolds on fords and its not horribly bad but its a pain. I haven't had any break bolts either.
Now on GM trucks I've had alot of manifolds warp and break the bolts and on most I could drill the old bolts out and use new ones. However a few the firewall prevents drilling so I had to remove the head in order to remove the bolts.
Now on GM trucks I've had alot of manifolds warp and break the bolts and on most I could drill the old bolts out and use new ones. However a few the firewall prevents drilling so I had to remove the head in order to remove the bolts.
Senior Member
Joined: Jul 2007
Posts: 3,291
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From: Beaverton Or.
It's very common in our trucks. I paid around 350 bucks at an exhaust shop to have all the studs replaced with a new gasket. 3 were broken. Didn't need new manifolds, just corroded studs causing a leak. It has happened to my dads f150, a co-workers and is starting to on the F150 I have now. Not something I wanted to tackle myself just for the mere fact that I hate extracting broken things. Always seem to mess the threads up. But it is do-able. I am tho thinking about doing mine on this truck soon, before studs break off. Good time for LT's 
yep, drill and easy outs. If your lucky, there will be enough left sticking out that you can grab with vise grips, soak them the best you can and remove.
yep, drill and easy outs. If your lucky, there will be enough left sticking out that you can grab with vise grips, soak them the best you can and remove.
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Joined: May 2010
Posts: 59
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From: Athens, TN
had a buddy of mine do it same thing with mine broken studs, warped the manifold pretty bad but we got one from a junk yard for around 50 bucks. he soaked all the studs down really good with pb blaster, the kind that acts like a magnet it wicks down to through the threads really well.