I have a 2001 f250sd with a 5.4L it has just under 180,000 miles on it and i noticed today that the right exhaust <nobr style="font-weight: normal; font-size: 100%; color: darkgreen;" id="itxt_nobr_1_0">manifold</nobr> has a crack in it. Its located on the underside in the back of the manifold. I also noticed that both the upper and lower nuts and studs on the back exhaust port are rotted off. I cant tell if they are sheared off at the head or if they are sticking out a little. I also noticed the other 6 nuts are rusted really bad, so bad that i don't know if i can even get a wrench or socket on them.
I have been told that this is a common problem with this manifold. Does anyone have any tricks hints or ideas without taking the head off... whats the easiest way to get the old studs out that are broken and get the old ones out that are not broken with out breaking them so i can put all new stainless steal studs in. I have read it can be done with the head on the truck but can be a real PIA job. If ANYONE has come across this before please let me know how you did it
I would like to thank all in advance for there help and comments <!-- / message --> <!-- BEGIN TEMPLATE: ad_showthread_firstpost_sig --> <!-- END TEMPLATE: ad_showthread_firstpost_sig --> <!-- controls -->

 

I have heard that after soaking them with PB blaster, they usually come out without too much of a fight. They usually break off with enough left to get vise-grips on to remove them. I believe that the dealer sells stainless replacements that won't rust away.