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Ted J 
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Joined: 05 Jul 2010
Location: La Crosse, WI
Points: 18930
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 Topic: Ford Truck Mechanics
Posted: 18 Nov 2018 at 8:27am |
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My son Brian has a 2002 F150 with the 5.4 Triton V-8 in it. He has to take the exhaust manifold off and is asking for tips. Are these studs or bolts in it? He says it's a botch to get at. I haven't seen it so I don't know anything....else about it, but can ask (text) if questions arise.
Thanks guys!
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"Allis-Express"
19?? WC / 1941 C / 1952 CA / 1956 WD45 / 1957 WD45 / 1958 D-17
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bakwoodsfarm
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Joined: 02 Sep 2010
Location: Woodleaf,NC
Points: 511
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Posted: 18 Nov 2018 at 8:34am |
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I assume it is for an exhaust leak(very common). There are 8 bolts holding it to the head and 2 studs for the exhaust pipe. It leaks because the rear upper bolt breaks, so it will have to be drilled out. It can be done through the fender well, but only with a right angle drill. NOT A JOB FOR THE AMATEUR. You didn't say which side, but usually the pass side.
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DrAllis
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Joined: 12 Sep 2009
Points: 21745
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Posted: 18 Nov 2018 at 8:37am |
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Exhaust manifold STUDS with nuts and are metric. There are many U-tube videos on how to do that repair successfully. I did the right side on my 2003 last Winter and the videos helped. Figure on a new after-market manifold. Torch off the old nuts and slip the old manifold off the remaining part of the studs. The challenge is getting the broken off studs out of the aluminum cylinder head. Watch the videos.
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bakwoodsfarm
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Joined: 02 Sep 2010
Location: Woodleaf,NC
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Posted: 18 Nov 2018 at 8:41am |
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sorry, your right Dr. meant to say stud. About 50% of the time you can get a pair of good vice grips on the remaining stud to get it out.
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DrAllis
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Posted: 18 Nov 2018 at 8:50am |
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Both of my rear studs were broke off to about half length. After smacking them with a hammer a few times I was able to use a stud removal tool and they came right out. The other studs were similar, with one I finally used a torch lightly around the stud to warm up the aluminum cylinder head and it finally let go. Anti-sieze the new studs. I went to Ford and spend extra $$$$ and used their OEM gasket. I didn't like the looks of the replacement gasket that came with the new Dormann manifold. My old gasket never really failed, just the studs from heat cycles and rust. I also experimented on those two rear studs. I replaced them with Caterpillar Gr8 bolts and spacers to give the bolts another 1/2" of length to allow them to stretch instead of breaking off like the studs do. We'll see how that goes !! 8,000 miles later and all is well and I pull a 12K loaded trailer quite a bit in the Summer pulling season.
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HD6GTOM
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Joined: 30 Nov 2009
Location: MADISON CO IA
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Posted: 18 Nov 2018 at 5:05pm |
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That is probably why our ferd mechanic drops the motor out of the unit when doing that. I have seen him pull the front off the motor while he has it out.
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Sugarmaker
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Location: Albion PA
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Posted: 18 Nov 2018 at 7:01pm |
the 2009 F250 had that issue. They said it was easier to pull the cab to replace the manifold bolts. I picked out a new truck and drove the new one home. Good luck with those studs. Not one of Fords best designs! Regards, Chris
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D17 1958 (NFE), WD45 1954 (NFE), WD 1952 (NFE), WD 1950 (WFE), Allis F-40 forklift, Allis CA, Allis D14, Ford Jubilee, Many IH Cub Cadets, 32 Ford Dump, 65 Comet.
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fixer1958
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Joined: 13 Feb 2010
Location: kansas
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Posted: 18 Nov 2018 at 7:31pm |
It's an 02 so it's not that bad. As long as the rear ones are broke off and not the front. Most of the time they come right out. Sometimes not.
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1955CA
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Joined: 10 Sep 2018
Location: Ontario, Canada
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Posted: 18 Nov 2018 at 8:02pm |
Something for me to look forward to? LOL. I just got a rusty old 2006 F150 with the 5.4 Triton to use as a work truck. I just put the inner fenders back in after this pic. You can see the manifolds with the inner fenders removed but there is still a lot of stuff in the way.
If you have the driver side apart, check you oil dipstick too. They are also known to rot off on these trucks.  |
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Brian Jasper co. Ia
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Joined: 11 Sep 2009
Location: Prairie City Ia
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Posted: 19 Nov 2018 at 9:51pm |
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There is a drilling jig made by Pro Maxx that makes drilling the studs a breeze. Always replace the manifolds and get the studs from Ford as the replacements are stainless. My recommendation on the dipstick tube is pull the pan and drive it out. Those tubes like to cement themselves in place and break off easily.
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"Any man who thinks he can be happy and prosperous by letting the government take care of him better take a closer look at the American Indian." Henry Ford
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