My brother in Law up in Maine has a 2000 F-350 dually 4x4 V-10. The truck only has about 80K original miles on it however, he's had some serious issues with the manifold bolts.

Three years ago, he did a complete manifold bolt change out with the heads in place. A huge under taking as I advised him to remove the heads for better access. Naturally the bolts were all rusted in place and they all needed to be drilled and tapped.

He searched high and low for replacement bolts and ended up getting them at the Ford dealer. Seems that they were the only folks who carry the 8mm studs in the correct length.

Three years later and the bolts are rusted out again and he now has an exhaust leak on the right bank. Naturally this massive undertaking has to be done again on both sides. He's only driven the truck in the winter as it has a plow rig and a recovery unit out back. It's been driven 15K miles in the three years.

I need advise here that I can pass along to him.

Better hardware, source of supply or perhaps a different procedure to replace the bolts. Any and all comments are welcome.

He's not ready to throw in the towel and sell her yet but I fear he's about had it with this one.

Thanks guys, it's a great truck other than this recurring issue.

 

My 2003 did not break any yet . But every other year , I apply high temperature grease on all exhaust studs and nuts with a small painters brush . I can not control the thermal stress , but I can somewhat control the corrosion at least . High temp silicone grease should work too .

Good luck,