I have a 2002 f250 5.4 v8. Two of the manifold bolts are broken and I'm really short on cash to have someone fix it, nor do I have the means of replacing them. The manifolds themselves are ok....its just two bolts that are broken which are creating a very loud ticking exhaust. I was thinking of ways of rigging it until I'm able to afford fixing it. I was thinking: how about paying someone to just weld studs to the broken off bolts and attaching a nut to them to hold the manifold tighter to the engine? It looks like the previous owner pryed the manifold a little and squirted gasket maker around the seal. However, with the bolts broken off, exhaust air is leaking by the "gasket". Any ideas?

 

Nope replace them or leave them alone IMO. Stainless ones on ebay..

 

Which bolts are broken? The manifold to cylinder head or the manifold to exhaust pipe? B.

 

manifold to cylinder head

 

aren't stainless headers louder than manifolds? or do you mean there are some stainless manifolds out there? I'm wanting to go as quiet as possible but I'm hearing that new manifolds are prone to cracking.

 

I think he was referring to new stainless exhaust studs from ebay, not the manifolds or headers.
I installed a set of Bank stainless steel headers on my V-10 while doing the broken stud removal, they are pricey but very high quality units and the exhaust sound was actually just a tiny bit quieter with the headers (balance of exhaust still totally stock) vs the stock manifolds. I think that with the additional interior volume of the headers the gasses have a chance to move slower and cool down more reducing the noise a little bit.

 

Okay, depending on how much of the broken fastener is sticking out of the head, you maybe be able to remove the manifold and grab the broken fastener with a pair of visegrips and unscrew it to remove it. If it is broken flush with the head removing the broken fastener might be a real job depending on where the broken faster is at and your ability to access it. If you need an easy out, don't buy a cheap one. It will only compound the problem. IF you need to drill the fastener to use an easy out, be sure and center punch the fastener DEAD CENTER before you try and drill it out. Trust me, I have removed lots of broken fasteners and taking the time to get the hold dead center is critical. PLUS, you need to be able to drill it DIRECTLY inline with the broken fastener. IF the drill walks off and you drill into the head it will compound the problem. THAT will require even more work. But still fixable so don't fret too much.

When you replace the fasteners use good quality grade 8 or stainless steel fasteners. AND, coat the threads of the fasteners with a good high temp anti-seize compound. Trust me, you will be glad you did if you ever have to remove the manifold again.

Can you post a pic of which fastener is broken? Here is a link to SS bolt set. And a link to a good example of an extractor. B.

http://www.ebay.com/itm/FORD-4-6-5-4...lSC-AS&vxp=mtr

http://www.ebay.com/itm/New-Vermont-...4AAOSwvFZW8Di2