I'm 4 hours into removing the heads. Will it ever end? Anyway, my real question is this: Can I remove/install the heads with the exhaust manifolds attached to the head? My goal is to do as much assembly and disassembly on the bench due to limited space under the hood.

Also, there are no exhaust manifold gaskets installed from the factory so I was wondering will the exhaust manifolds leak if I put them back together without the gaskets? I think so, but I am surprised that they don't leak now. I suppose I could have the machine shop do a minimum cleanup on the exhaust manifolds and install them without gaskets. Or is it better to put gaskets on? Anyone with experience on this one?

 

I have not pulled the heads off my 93 4.0 Aerostar, but I did so when I rebuilt the 2.9 in my Bronco. I could not pull the exhaust manifolds off with the heads in the car because the bolts were frozen because of heat & rust. The machine shop guy said it happens to all the V6 Ford engines & other. He has to use a torch to heat the bolts or else they break. So if you can, I would pull the heads with the manifolds. Not sure if this helps but this is all I know about the subject.