Another 99 Expy manifold issue...
Thread Starter
|
Mountain Pass
Joined: Mar 2003
Posts: 153
Likes: 1
From: Va Beach VA
Another 99 Expy manifold issue...
99 expy 4x4 5.4 187K
Anyone done this nightmare? Where is the trick? Passenger side on this 5.4 broke off the back two studs by itself and has been ticking away for years, no biggie. Failed inspection for it....figured time to do it. Got all top nuts off (broken studs or other wise) and the front bottom one, now what.
NO ROOM TO WORK! I removed motor mount and jacked up as high as motor will go and I still cant get a socket, die grinder, cut off wheel, hammer and chisel on the bottom middle two bolts.... Whats the trick.
Out of 8:
2 broke by themselves
2 I cut nuts off with die grinder
1 stud broke clean off with socket
1 nut came off yea!!!
Still have not got to the fun part of trying to remove the broken studs from the head.
Thanks
PS: I have searched everywhere and most threads are about removing the studs I have not even got to that yet.
It had rear AC so the lines are running right in my face while working on this. I was thinking I could remove the motor mount and starter to have better access from the bottom. What a PITA!
Anyone done this nightmare? Where is the trick? Passenger side on this 5.4 broke off the back two studs by itself and has been ticking away for years, no biggie. Failed inspection for it....figured time to do it. Got all top nuts off (broken studs or other wise) and the front bottom one, now what.
NO ROOM TO WORK! I removed motor mount and jacked up as high as motor will go and I still cant get a socket, die grinder, cut off wheel, hammer and chisel on the bottom middle two bolts.... Whats the trick.
Out of 8:
2 broke by themselves
2 I cut nuts off with die grinder
1 stud broke clean off with socket
1 nut came off yea!!!
Still have not got to the fun part of trying to remove the broken studs from the head.
Thanks
PS: I have searched everywhere and most threads are about removing the studs I have not even got to that yet.
It had rear AC so the lines are running right in my face while working on this. I was thinking I could remove the motor mount and starter to have better access from the bottom. What a PITA!
Thread Starter
|
Mountain Pass
Joined: Mar 2003
Posts: 153
Likes: 1
From: Va Beach VA
Yes skirt and inner fender is out. Still cant get to the bottom middle two nuts with any power tools.
Thread Starter
|
Mountain Pass
Joined: Mar 2003
Posts: 153
Likes: 1
From: Va Beach VA
Was going to try and save it and only replace gaskets and studs....like your thinking tho
Senior User
Joined: Jul 2003
Posts: 270
Likes: 1
From: tampa bay area
You must be talking about the 2 which are buried down behind the motor mount. The only solution I found for those was to unbolt the cylinder head and lift it up so the nuts/studs were exposed. NO, I am not suggesting you do that. I was taking the cylinder heads off for a reason at the time.
Aside from what I did, my thoughts are removing the pass side motor mount entirely. I don't know how else you can get anything in there to loosen the nuts or to physically get the studs out of there. You will have to find a safe way to support the motor while you are doing this of course.
EDIT: I missed the part where you already removed the motor mount. I got nothing for ya, sorry. Let us know what you come up with.
Aside from what I did, my thoughts are removing the pass side motor mount entirely. I don't know how else you can get anything in there to loosen the nuts or to physically get the studs out of there. You will have to find a safe way to support the motor while you are doing this of course.
EDIT: I missed the part where you already removed the motor mount. I got nothing for ya, sorry. Let us know what you come up with.
Fleet Owner
Joined: Apr 2008
Posts: 24,316
Likes: 5,127
From: 0,0,1
Excellent advice! Use solids supports like jack stands. Never...Ever trust a floor jack when your body parts are at risk.
Thread
Thread Starter
Forum
Replies
Last Post
TheRooster
1968-Present E-Series Van/Cutaway/Chassis
14
Sep 21, 2025 01:47 PM
