Thank you! I went here:

http://cgi.ebay.com/ebaymotors/Dorma...item519967e9f9

And that one fits, this one:

http://cgi.ebay.com/ebaymotors/Dorma...item519967ea09

Does not, even though ebays parts checker says it does. So heads up boys, that thing isn't 100% accurate.

It seems many places are out of stock on the pass side. autopartsdirect2you is on back order and seems to have the best price. I'll be giving them a call tomorrow to find out when they'll be back in stock.

 

I'm not sure what you mean. - What does not? Or does not what lol ? Fit ? Says it does. All are the same, actually as far back as 97. 97-03 are all the same. Like I said tho, make sure it's the 5.4L . They say the 4.6L is compatible, BUT, that's only at the heads. They have a different radius at the exhaust pipe connection.

 

Sorry, let me explain. In the 1st link it says 5.4L in the title. Description says it fits the 5.4. The 2nd link is for the 4.6 HOWEVER ebays little parts selector says it fits the 5.4 when it does not.

 

Okay, yea I seen that in the link as well. The pipe connect on the 4six manifolds are a little different because the 4.6L and 5.4L blocks aren't the same size. The 5four is taller.

 

Got the wheel well cover off on the pass side and saw this:







Few questions.

Photo one shows the exhaust where the leak is coming from, a hole is in the side and it's smoking like crazy from there. I noticed some black stuff coming from it too. What is that? Burnt oil? You can see it in the other photos where I spray painted from MS paint. It's mainly towards the back, but even with the engine revved up, I saw no oil, or anything coming from the gasket. Could that be from the exhaust leak over time? Also saw on cylinder 4 the nuts are completely gone, so that's 2 less to mess with

LMK your thoughts, still hunting down a pass side manifold. Thanks!

 

That's alright. Just replace them.

 

In 99 the 5.4 engine the exhaust manifolds are a little different. In 97-98 they had 'humps' between the cylinders, whereas the 99 and up exhaust manifolds went to a flat design. I know this for a fact, because I had a 98 expy, traded it on a 99 expy and they indeed changed the design for the P.I. heads. I'm sure the 97-98 will bold right up, but the design of them is way different. Here's pictures of the right side manifold in both years:

1997-1998 Right Manifold


1999 - 2003 Right Manifold

 

The Drivers side exhaust manifolds are really different, but it appears they'd bolt up but I'm not sure if they are more restrictive...

1997-98


1999-2003

 

Yep, the 99 + are a better design as far as flow. They just need to be 5four specific. Otherwise, those will work.

 

So far I've gotten two out, I've wire wheeled them to no avail. The nut is so rusted, it's welded itself to the manifold. I have an air chisel but that's only dulling out the bits. The sockets are not grabbing either. The two that came off, took almost 6 hours to do. But the threads came out without any issue.

The two bolts and nuts that hold the cat converter to the manifold the 15mm ones, aren't budging either.

Any other tricks of the trade to move this project along are welcome.

 

Think it's time to scrap it. Grab a few beers and some buddies.. fire it up with no headers, take it up into the woods and run the **** out of it. Jump it, do whatever. Then find a big open field, say a prayer and light it on fire. Call the insurance and report it stolen.

J/K

 

LOL if only....

BUT I GOT IT OUT! Photos to follow in a moment.

 

^^^^^ A fathers day present to me, from me

And with that toy this came right out...


As you can see, the 1st and last hole has what looks to be oil coming from it. What do you think?



I put my finger in there to see how moist it was (that's what she said) and it wasn't that bad, you'll see the line in the photos.




9 gaskets was the final count when I took this off...


Some stacked 3 deep


One of my labs coming over to see what all the noise is



And a cold Narragansett Summer Ale to celebrate the half way point.

Now to get some PB blaster and get the rest of those bolts out.

 

You crack me up

Nice SawZall , at least your purchased a corded one and Milwaukee to boot!

I use a couple Porter Cables myself. Why have one when you can have two



You gotta nice one tho, they sure are pretty when new. You want to make sure to only purchase Bi-metal Blades for saw, don't go cheap on blades or go thru them to quick. How many amps is that one ? That's a nice one for sure, I have quite few Milwaukee tools, - top notch.

Looks like your having fun lol.

__________________________________________________ ___________

Well, right now you have it perfect for welding a nut on those broken studs. Go buy a belated fathers gift for yourself. A little Mig Welder comes in handy. You can get a cheap one at Harbor Freight for about $100.

You can attempt vise grips, but I'm not sure that's going to do it. Heat will help as well. Heat will break down the corrosion locking the dissimilar metals together. That's why you would get right on a welded nut asap after welding. Easy to weld with a Mig, real easy. I can tell you how if you get one.

 

Ive been doing carpentry for 15 years. When it comes to sawzalls, milwaukee is absolutely the best. Still have the original 3 that I bought back in about 97. Never an issue. Have gone through at least 4 dewalts and a few others since. Those shocks look like they could use some help...