Does your EX have an EGR valve? Mine did not so I bought the #49138. If you do have an EGR it will be on the driver's side exhaust manifold, if not the manifold will just have the solid flat round boss where the valve would have been.
This is my non-EGR manifold.

 

As an FYI... I did my drivers side and only broke 1 stud. My biggest issue was removing the studs holding the manifold to the y pipe. I have the part number somewhere if anyone needs it. I had to cut mine, there was no head left on the nut.

Sidenote... I changed the studs and gasket and kept everything else stock for now.

 

you simplified that great for me, the pic was a great help too.

Thanks

 

Well, I just checked mine and it looks just like the pic of yours. So, now I know which one to order.

 

I'm looking forward to following your install!
I held out and waited for a good sale at AutoAnything.com, they had a good price on them and the sale knocked off another 15% along with free shipping.

 

Auto anything doesn't list the torque tubes on their site. I have not contacted them I just checked online.

 

Ok, they don't list them under Excursion, I found them by selecting f250 as my vehicle, then no EGR and then the correct part number "49138" showed up. So now I have to watch for a huge sale.

 

Out of curiosity, since I'm going to be tacking a similar project myself, what spec of mig wire did you use? I've read that the stock studs are stainless (not sure what type of stainless though). Did you use just mild carbon steel wire (ER70S-2 or ER70S-6) or did you use some sort of stainless wire?

 

Just plain old ER70S-2 (pretty sure thats it), same stuff thats in the machine 99% of the time for general fixxing/fabbing/playing in the garage. It worked well and the stud that was broken off almost flush with the head surface took the weld very well and spun right out, the other stud was too far inside the head and my little 110v machine couldn't get the weld hot enough in the deeper hole.
Good luck with your install, and stud extraction, it can be a pain but when it's done you will be smiling!

 

To add, I used Lincoln .035 Flux Core wire when I did mine. One of the studs was 2-3 threads below the head, and got it welded up and turned out. But I did drill a hole in it first, than welded the hole shut, and continued to add weld tell I could weld a nut on. Than some taps with a hammer, some penetrating oil, and tighten, than loosen, wiggle back and forth n slowly turning it came out.

 

I started mine tonight. We got the inner fenders out and the shocks. Everything is sprayed with penetrating oil. I also cut the bolts off to the Y pipe. We're trying to figure out how to reach the O2 plug on the right side. We have 8 broken studs, 2 are flush with or below the head(maybe 3).

 

Anyone know how to get the steering shaft off the firewall?

My wife and I will tackle the studs tomorrow. Prayers would be appreciated!

 

Steering shaft shouldn't need to be moved. I didn't move it when I did my Hedmans. I even did all the install from the wheel wells

 

Now I feel dumb Dave, that probabily would have worked for me too. But I was trying to shoot the wire from the MIG through the hole in the nut then into the stud hole in the head and couldn't get decent penetration. I should have done like you and built it up first then put the nut in place. Sometimes I can't see the forest for the trees!


That one O2 plug is waaay up there, I had to squeeze my fat arm in pretty deep to get to it! Use Dave's welding method, don't be a dummy like me!


I didn't touch the steering shaft, I think that was Christina (Sammie).

Yeah, I would leave the steering alone, the Banks seem like they are a little bigger than the Hedmans due to tube routing, I don't think you could put the Banks in through the wheelwells. Mine went in from below without much drama, the oil dipstick was the thing that fought me the hardest, it didn't want to come out of it's hole, lots of wiggling and twisting was needed. Some folks have had the dipstick tube break off if it's rusted, I got lucky and mine was rust free and eventually came out in one piece.
Good luck!

 

Thanks for the help!