I have a 1999 F150 with 5.4 with 186,000 miles on it and found 2 broken studs on the pass side manifold! I know this is a problem on all 97-03 F150's with either 4.6 or 5.4 my question is why this hasn't been recalled???? I have had 3 of these trucks and same issue on all three!! My current 99 I just bought and the guy was the original owner and had them replaced twice once at 85,000 miles and 2nd time at 150,000 miles the dealer said they put new and improved ones in and had no issues with them! Bull sh-- it is only 36,000 miles since they were put in and I have 2 broken and they all look like they are about to fall apart! I can't believe how bad they have rusted the nut on the stud isn't even the correct size anymore they are that far gone! I put every kind of penatrating oil I could find for 3 weeks everyday and tried to break them loose and only got 2 to come out both studs came out the nut wouldn't even budge the rest snapped off flush with the manifold! I tried every visegrip I own, torch , and couldn't budge any of the broken studs!! I then took my welder and welded a brand new nut on all the broken studs and got 2 more out that way but 2 snapped off flush with the head the other 2 snapped at the weld so I welded another nut on again and got them out! I then bought myself a side drill to drill out the remaining 2 studs out to re-tap the holes! Finally after 25 hours of fighting on the pass side I finally was ready to put my header on with all new header bolts! I wasn't going to waste my time with factory rust I have put headers on all 3 of my trucks and would suggest the same to anyone who has this problem!! Headers $199 with hardware and gaskets do it yourself or spend $1500 at the dealer for factory rust that only lasts 50,000 miles its your choice!!

 

(Update driver side manifold) I had a little more luck on the studs they must have got smart and used some anti-seize on the threads as I always do on anything aluminum I only broke one off the rest came out! The only issue I had was the oil dipstick tube snapped off trying to pull it out of the block to put the header on but JB weld did the trick so my truck is back on the road sounding good and breathing better not to mention more hp and mpg!

 

I agree! There should have been a recall. Every F150 will do it sooner or later. I have a 03 Fx4 screw I bought from Florida almost 2yrs ago and I have a broken pass. Side rear stud. It's not a rust issue on mine...all of mine are clean. I just have a failed stud. I found it when i was replacing the starter. It looks like its broke off flush in the head too. I'm not going to tackle it till spring or we get warmer weather.

I've searched all over online and can't find a replacement stud that's stainless...

 

You need to use the ARP stainless studs. Call them, don;t look online. Its too hard to narrow it down.

 

Why is this a recall issue? These trucks are not new. Not even within 2 generations of a new truck. My father did the same to his F-350 V-10. He had multiple broken studs. My truck has a newer engine in it and haven't had the issue. My tank straps broke and replaced them before the recall. then my frame rusted thru where the straps attach. Ford didn't fix it. These trucks are old. Maintenance keeps them alive. It's cheaper then a car payment for me. I'm just glad they are engineered to last this long.

 

So...what your saying its perfectly normal for your manifold studs to break? This is not a maintenance issue...its a Ford problem! My 03 I drove to Florida to buy it and its clean. Zero rust but yet I have a broken stud. Granted its 9yrs old but it only has 80k on it and has never been exposed to salt till just last week. I guess I just don't expect the studs to break just like that with rust not even a issue.

 

Keep in mind dodge has this same issue on aluminum head V8's. Not normal, but its the cost cutting taking its toll. Not a whole lot we can do about it unfortunatly. The cost cutting will only get way worse as time goes on.

 

Salt isn't the issue. The problem is the aluminum head and the cast manifolds heat and cool at different rates causing the studs to break.

 

I know it just sucks...I've had a number of these trucks and they have all done it. Other then that they have been pretty tough.

 

Ford should know its a problem that is why they should recall it but look at all the money they are making by not recalling it! I guess it should just be the first thing that gets changed if you ever buy one even if they are not broke yet the sooner the better!! At least that way they come out before snapping them all off like I did trying to change them at 185,000 miles!

 

Cheap, chinese steel

 

just did mine at 200k and didn't break a single one. only the two that were already broken. but every one came out very easy. put in stainless bolts instead of studs with a new manifold. only took about 2 hours. 99 f150 5.4L

 

That is great I wasn't so lucky but I live in Minnesota were the roads are made of salt half the year so rust happens in 1/4 the time! The manifolds and bolts rust so bad there is nothing left of them the nuts are 2 sizes smaller than they were originally! I do everything I can to avoid the salt I take the roads that are not plowed to avoid salt on the highway! That is why I have 4x4 I would rather drive in the ditch than have my truck rust out after a few salty winters!

 

I did the DS years ago...all went well. About a year ago I heard the tick-tick on the PS. sure enough.....back one busted off. But if you notice....they always seem to break flush with the manifold. The hole in the manifold is bigger than the stud...I assume for expansion. Meaning...there are threads still there. I went to Ace Hardware and got a metric flange nut. I JB welded that nut.. flange to flange.. to a 9/16ths nut. after it dried I had a buddy put a tack on it. Then I ground the metric flange nut in the shape of a cone....just enough so it would walk under the manifold. It will grab about 3 threads as you tighten it. It's been over a year now and still holding tight.