My dad has a 95 f350 psd that has had an exhaust leak on the drivers manifold to head connection for some time now. At least one of the bolts is broken. I did some searching and raised a couple questions. I hear some talk of planing the manifold but I was hoping to get this done in a day. What about the bolts, should I get all new ones from Ford? Gasket or no gasket?
The oil cooler is also leaking so I figure with the manifold out of the way might as well fix that too. Is it going to be easier with the manifold out of the way?
Any thoughts or tips appreciated.

 

Depending on how much the bolts are rusted, one day might not do it. I had to soak mine for several days before they would come out but I was real cautious. I also did my oil cooler when the manifold was out of the way. I would defiantly have the manifold planed off at the machine shop and I used gaskets.

 

I'd soak them suckers in pb blaster for at least a week. There a bear to get out. I ended up breaking the heads off 3 and welding nuts to them. Good luck

 

If the truck has spent any time in the rust belt, have the new bolts on hand. When I did this to the 96 C&C, I could get only 1 bolt out.The heads of the bolts were so rusted that a good 8 point socket would not hold on the head. I ended up cutting the rest of the bolts off with a saws all, leaving a stub of the bolt sticking out of the head. The bolts were so rusted in the manifold that I was afraid I was going to break the manifold driving the cut off bolts out. The stub bolts were removed with either a pair of vice grips or one of those reverse grip sockets. When I reinstalled the manny, I used a gasket, but did not plane it, and used a liberal amout of anti-sease on the bolts. Removing the oil cooler would be easier to do with the manny off, as it would give you a little more room to get the cooler out.

 

I see rockauto has a new manifold with gasket and "all required hardware" for $100 or so. I might just go that route.

 

Search doorman.u won't still want to buy it.bad track record.

 

The manifold only comes with the 2 bolts and nuts for the flange, not the 8 bolts to attach it to the head. Are grade 8's ok or do I need to get them from the dealer? Anyone know what size they are?

 

I don't use gasket's on exhaust anymore. permatex ultra copper is what I run anymore. you can get it at just about any parts store.


2 Pcs Permatex Ultra Copper 81878 Sensor Safe High Temp RTV Silicone Gasket | eBay
http://www.ebay.com/itm/like/400495551561
not trying to get you to buy these its just easy pics to get


sanded mine with a flat sanding board head and manifold. been there 4 years so far without any signs of a leak. uppipes an turbo also

 

I just did my oil cooler last night and it wasn't really hard. I am not sure on 2wd if it is harder to get the cooler out, but I don't think it would be dramatically easier one way or the other. So if pressed for time you could always come back to the cooler. On the other hand, if you pull the cooler first, you might have more room to struggle with the manifold and that would be an advantage.