Exhaust leak - fixed! - Ford Truck Enthusiasts Forums

2004 - 2008 F150 2004, 2005, 2006, 2007 and 2008 Ford F150's with 5.4 V8, 4.6 V8 engine

Exhaust leak - fixed!

Thread Tools Search this Thread
Old 10-02-2011, 10:40 PM
ShootinOK's Avatar
ShootinOK ShootinOK is offline
Senior User
Thread Starter
Join Date: Nov 2005
Location: Claremore OK
Posts: 118
ShootinOK is gaining momentum as a positive member of FTE.
Exhaust leak - fixed!

I developed the annoying little tick just before 100K miles.
Dealer quoted me $1100 – unless studs broke; then add $$ for each one.
I decide to tackle it myself.

You need to take off the inner fender well, the starter, unbolt the exhaust from the manifolds on both sides and unbolt the hangers all the way back. If you have a transmission skid plate; take it off to allow the entire exhaust to move back out of your way. Now I sprayed all the studs with Kroil and let it set. I took my time and was able to get all the nuts off and all the studs out without breaking even one!
I had to take out the studs to get the manifold out. Otherwise I think I would have had to unbolt the motor mount and lift the engine to get it out.

#4 cylinder was the culprit and manifold was warped.

I bought my new manifold at Napa and it came with gaskets and 4 studs. $90
The strange thing is – the studs are the wrong size. ??.

I decided to go ahead and buy new studs; so I got them from Ford dealer - $20 for all 8
But they don’t come with new nuts…

Putting the new manifold on went very well….until… I was torqueing the nuts and one let go (tight then loose) meaning I had a stripped hole.
No way to get a drill in there; so I filed the end of a drill bit into a hex and it fit in an 8mm socket. Drilling out the aluminum was easy with a ratchet and a few extensions – just went slow with light pressure and I backed out often. Now I tapped it out and put in a helicoil insert.

This time it tightened up OK.
Now back together and it sounds GREAT!

Definitely a time consuming job, just because of the amount of work to get there, but well worth it for me to save a thousand dollars!
Reply With Quote
Old 12-14-2011, 06:41 AM
jbc19d's Avatar
jbc19d jbc19d is offline
Freshman User
Join Date: Feb 2011
Posts: 28
jbc19d is starting off with a positive reputation.
I started on mine last weekend...same exact problem at same mileage. Its has been a pain in the a**! But im in the military and called the auto shop on post and they want $180.00 to change both sides! Im definitely taking it to them to do and its warrantied. The local exhaust shops wanted 800to to do it. I just hope the manifold is not warped.
Reply With Quote
Old 12-14-2011, 03:54 PM
60DRB's Avatar
60DRB 60DRB is offline
Elder User
Join Date: Dec 2009
Location: East L.A.
Posts: 696
60DRB is gaining momentum as a positive member of FTE.60DRB is gaining momentum as a positive member of FTE.
I hope it's not the one at Ft Hood...
Reply With Quote

Related Topics
Thread Thread Starter Forum Replies Last Post
1952 Ford F-1 build ADOR 1948 - 1956 F1, F100 & Larger F-Series Trucks 128 04-17-2017 11:39 PM
HOWTO - Fill in the speaker holes/cracks in your dash girlwithatruck '80-'86 HOWTO's 74 03-03-2017 12:48 AM
1981 F-150 Ranger XLT "New Mexico" Build Thread dohc_chump 1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks 18 12-28-2011 11:31 PM
What's missing? (460 emissions equipment, pic heavy) Galm_2 1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks 24 08-14-2011 10:34 PM
Interior Mod: Custom Cupholder girlwithatruck Appearance & Dress-Up 9 10-09-2009 11:40 AM

Go Back   Ford Truck Enthusiasts Forums >

05, 08, 1986, 1996, 2004, 58, 73, escape, exhaust, f150, f250, fix, ford, leak, motor, tick

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump

All times are GMT -5. The time now is 12:22 AM.

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.