2003 F350 short bed 6.8L V10---On start up a slight tap sound, almost like a cranky lifter, but it is an exhaust manifold leak. At the bolts, I am not sure. This has been this way for 5 years, no better no worse.


After I run about 2 to 3 minutes it seals itself. Not a hint of noise. Due to heat, something is expanding to seal it (aluminum).


At my annual PA. State Safety Inspection the Tech says 'that has to be corrected if it worsens', but It does not fail inspection.


This puzzles me.


How is the call made for correction. A flip of the coin, a guess and is it serious enough to fail inspection. Is this normal with the 6.8L or V10s.


I know the cost involved for a fix is big league, but can it be justified.


TRUCK RUNS GREAT !-----your thoughts


fossil

 

Crawl under and snug up the two nuts ????

 

The V-10 is pretty well known for this very common exhaust manifold stud failure.
Is this leak at the head/manifold joint or at the manifold/down pipe joint? Take a close look at your exhaust manifold studs (the ones that go through the manifolds into the heads), there should be 20 of them in total, I'll bet that you are missing a few.
PA can fail a vehicles on safety inspection for any exhaust leak, since it is closing up with engine heat quickly the tech is turning a blind eye to it, but like he told you, if it gets worse it will not pass inspection.
The shop quotes I've seen mentioned around here seem to run from $400 to $800 to remove the manifolds and replace all the exhaust studs with new. I had 2 broken and missing studs on my V-10. I took advantage of that issue and my desire for improved performance and removed my manifolds and studs and replaced with a set of Banks headers and new bolts. I did the job at home and removed the 2 broken studs without too much drama, welded a nut to 1 and it spun out fine, the other I had to drill and use an Easy-Out on. The other 18 non broken studs came easily with a hammered on socket and ratchet.

 

If you are reasonably skilled with hand tools, you can use a reverse twist drill bit , to remove the broken studs , and install new.
I have done this exact thing, only replacing the broken .
Have had no more break , and has been good for 3 almost 4 years.

 

If you go over to the V10 forum there is plenty of info on how to do this repair right and many examples of doing it wroung as well. Take your time with proper preperation you can do it.