I've been looking around for info on the broken exhaust stud problem and and have a few more questions.

First, has anyone tried to replace the studs with a stronger grade stud? Sounds like a good idea but I'd rather break studs than pull the threads out of the head. How about a more ductile material?

Second, is there a gasket that may be a little more resilliant and allow the manifold to move around a bit and still seal?

Third, is this condition less prone to those running headers? (Yes honey, I NEED to buy headers)

Fourth, if I do nothing but replace the broken studs how long before I'll have to do it again?

Any info will be helpful.

Thanks,
Joe
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I have two broken Ford Factory studs after one year of full replacement. Not that this is the rule but it just is true. Some on here have used other grade bolts, not sure of the outcome. I just put factory gaskets and bolts on my new motor I built. I was going to get headers and was looking at hedman but due to the problem on the 'hedman headers with pics' chose to go factory.

 

The one true way to get rid of the broken studs is to run headers. Doug Thorley makes great headers, but pricey!

 

I used Stage 8 locking bolts on my hedman hedders.No rust,no problems. Dont know if they would work on stock manifold. My new set of hedders is shipping today.

 

Is it really true that headers "fix" the broken stud issue? I've read it both ways on here. I've been replacing studs on mine about every 2 years or so (5-6 each time). Had the truck since 2005. And I'm due right now... Getting an awful whistling when the truck is cold.

I was talking with my mechanic and he said that it typically won't stop the studs from breaking, but If the manifold needs replacing, its a good jump to go to headers.

But if headers make the problem better, ie less chance of breakage, I might bite the bullet and move to headers whether I need a new manifold or not. If it saves me replacing studs down the road, its worth the cost...

 

It really depends on trucks use. Obviously driven all winter will kill studs, but the header bolts have a less chance of getting coated with salt, dirt, etc.

 

I’m just now finding broken studs on my 03 truck and it’s only got 81K miles on it. I’m guessing it’s from the load being put on the engine while towing. The exhaust manifolds get real hot climbing grades in the summer towing a 10k trailer. I sure wish there was a good fix for this. Headers seem like a good alternative but I’m concerned about passing emissions, engine noise and the longevity of the headers. <?xml:namespace prefix = o ns = "urn:schemas-microsoft-comfficeffice" /><o></o>

 

Purchased a complete exhaust set-up manufactured by Gale Banks. All stainless steel. Consisted of headers, y-pipe, muffler, tail-pipe, and heat shields. Installation was straight forward without much hassle, considering what your doing. Nice material, excellent beads on the welds, beefy flanges and gaskets to mate to the exhaust manifolds. One time installation, I have had no problems whatsoever with the actual exhaust pipe(s)/material in the past nine years. I would recommend purchasing SS clamps since the those provided will rust. Banks may include SS clamps with the exhaust system now, dont know. Well worth what I paid, in my opinion. To date I have not had to replace any factory studs, possibly due in part to the thick header flanges. I truck has been run hard as well. For instance, I pulled a 18K pd. tri-axle trailer (yes I know) from omaha to D.C straight through, followed by a quick-turn. Ive done this three times, truck never missed a beat during heavy use. Emissions, starter engagement, wire melting, gasket blowout have never been an issue either. Definitely worth looking into. A bit pricey, but I feel in this instance I got what I paid for.

 

My 03 had them broken at 50k a few years ago and rarely has any load on it. Its the weather and location plus material they are made from. Threads rust away, nuts pop the stud with heat expansion over time. This is a Ford problem on v-8 trucks also.

 

I was wondering if ARP had better replacement studs. I haven't seen anyone comment on them. Anyone tried them?

 

I also have the Banks kit on for only 6 months but trouble free.

 

I sent ARP a note. I'd like to see if they have anything that may work.