Exhaust Manifold Leak with broken Bolts!!!!
 

Today while under my 04 F450 dump for an oil change i noticed heavy black carbon over the exhaust manifold and head. On the driver`s side rear exhaust port (cylinder #8) the upper and lower bolt heads are broken off. Now i know why it is leaking but can understand the broken bolt heads. only ever been worked on by dealer, who i would not think would do that, also dont recall any exhaust manifold work ever being done. Anyone know of this being a common problem??? Also,can i get new bolts, and the metal gasket ford offers to repair it, or if it has been leaking for a while would it warp the manifold too much for it to reseal. Thanks Peter G.

anyone ever have this happen?

thats weird, it sounds like they broke... this has to be a known problem or something!!

you can get the EM gasket set and replacement bolts, no problem. That manifold is easy to remove(don't forget the EBP sensor tube). Hopefully the old bolts come out easily for you. The manifold should be fine.

I worked on a buddy's truck last weekend and the same bolts were loose on his exhaust manifold and leaking.

we see it from time to time. not common. we used to get 460's in that way left and right.
Ive seen more 6.4 do it latly. repair wil be basied on the finding if the maniflod is warped.

Thanks for the input guys, just out of curiousity do they sell aftermarket / performance headers for the 6.0's?

never seen a set myself.

i have never seen a set either..

My 04 F350 6.0L (187k mi) is in the shop right now getting one broken exhaust manifold bolt replaced. Mine was/is the passenger top rear bolt. I am having them replace all the bolts on the one side and adding the gasket. They estimated 2 hours for the repair. The book rate is different from passenger side vs drivers side. I believe the drivers side was quicker. Both sides were estimated at 3.5 hrs.