Changed pass side exhaust manifold gasket Saturday
The title says it all. I have a buddy that is a mechanic at a Ford dealership and he offered to help. He has his own shop on the side also and that is where we did it. The truck is an 03 Screw 4X4 5.4. Up until this point, I only had the tick when cold and it went away when warm. No bolts were broken. Finally, last weekend three of us went to Columbus for a Ford swap meet and it got louder. I crawled under the truck and the top nut had removed itself on #4. The stud was flush with the manifold. So I called him up and took the truck to his shop. I was scared to death. Anyway, I removed the wheel and inner fender. We removed the downpipe and then hit the studs with a Snap On socked that is for rusty bolts and an impact. They have spiral "teeth". Anyway, all of the studs came out with the nuts attached except #4 lower. It snapped off way inside the head. The stud that was previously (top #4) broken, came out easily with a stud puller. Now to the bottom one. I could take a pick tool and spin the broken portion back and forth. So, we simply drilled a small and used an easy out. My buddy said that if left for a long time with a broken stud, the threads can carbon up and there lies issues with removing it easily. Anyway, I used new studs from Ford and Fel-Pro gaskets. They have more "cushion" to seal off the manifold where it was pitted. I wire brushed it and put it back together. The job took 1 and a half hours. He said he typically torches the downpipe studs off and just replaces them, but mine were in good condition. Sorry so long, but I read several posts where people were hesitant to do this. It is a little intimidating, but it can be done at home.