I have 4.6 that has a small hole and crack in the passenger side exhaust
manafold. What is the best procedure for removing manifold without
breaking off a stud. Any suggestions would be appreciated.
Jim

 

I have had great luck with ford manifolds, bolts, etc.
Stuck bolts and a torch are meant for each other.

 

spray thoroughly and generously with aero-kroil or pb blaster a day before the job. drive around after spraying it, spray it before bed, spray it again before you start the job.

 

It it a bolt that holds the exhaust manifold on or a nut on a stud that holds the manifold on. I have a torch, would cutting away some of the manifold make it easier to get at the
bottom bolts?

 

There is a product at Advanced Auto called Thermoweld. It is a cold weld mixture that can be used on exhaust manifolds to to repair holes and cracks. Has anyone have
any experience with this product for repairing exhaust manifolds

 

Welcome to the site. I haven't used that product before. We do carry a stock replacement manifold for you application though.

Here's a link to it on our site if you would like to check it out.If you have any questions I'd be glad to answer them for you.

Ford F150 Exhaust Manifold

 

You will want a new, good used manifold. I've tried the putty stuff and it wont hold for long. Even welding it is a hit or miss deal. The heat from the welder makes more cracks appear. Fix it right, you'll be much happier in the end.

 

Just remembe to be careful, our f150s have aluminum heads that can make the process of taking the bolt a little more challenging. If a bolt breaks use a bolt extractor and make sure you do not drill into the head or you will have a bigger nightmare to deal with.

As said before a nice coating of PB blaster a few times before the job will help immensly.


If you are experienced with aceletaline (SP) torches you can heat the bolt (make sure its just the bolt) to almost red, hit it with a hammer, and unscrew the bolt. It breaks down the electrolisys process that creates a bond between steel and aluminum metals. Over time the metals are know to bond together by electrolisys.