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I have a 84 f150 5.8w that has a exhaust leak in the exhaust pipe. It is leaking around the Y connection I believe. I think it is original and is in need of replacement. How hard is it to replace and what problems should I expect? The connections to the manifold are what I am afraid of, any help would be appreciated.
I replaced the head pipe on my '93 300 this weekend. After 200K miles, I was also most concerned about the connection to the manifolds.
I hit the four studs several days in a row with a good spraying of PB Blaster. Prior to removal, I let the engine warm up a bit and used a long handled rachet to free the studs. Not a lot of pressure, and I was careful to work it back and forth a bit to loosen any surface rust.
Also, I used a sawzall to cut off the head pipes a few inches below the flanges. More room to work!
Slorch hit it right on. Shhot the bolts and nuts with something like PBBlaster. I love the stuff myself. Do that several times before attempting to remove the nuts. Also, like Slorch says, back them off about 1/2 turn to 1 turn max at a time, then turn them back the other way just a little to clean the threads. If they are real rusty, you're essentially using the nut as a die and "cutting" new threads. Be patient. I rushed a job on my old truck removing the exhaust, 4 broken bolts and probably several bones in my hand (not really but it sure felt like it), I was wishing that I had taken the time during the previous week to spray them with something to loosen the rust.
One other thing I forgot: Disconnect your battery when removing/installing the head pipe. When installing the new one, I made contact with the starter and had my own little fireworks show!
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