I've got the dreaded broken exhaust manifold studs on my 2004 F250 V10. I don't drive it much (just 50,000 miles in 10 years) and confess I've ignored the hissing for quite a while. Is there really a permanent fix for these broken studs? Or should I expect to be replacing broken studs every 2 or 3 years?

If there is a permanent fix what is it? Special studs? Special manifold? I want to keep this truck a long time and don't want to be replacing these studs every few years.

I'd appreciate your wisdom on what I should do to have the best chance at a long term fix.

 

Stainless studs (after you get the old ones out).

 

Thanks project, will local auto parts shops have these as normal replacement parts or the Ford dealer? How many miles on yours without problems after the repair?

 

The stainless studs will break, my 04' had stainless studs the nuts were some kind of powdered steel. The stress from expansion/contraction from heat/cool cycles is what breaks them. I went with a set of Doug Thorley headers and stud breakage was fixed for good. However there are couple disadvantages to the headers.

 

instead of stainless nuts, fix the problem by removing the studs completely and using a stainless bolt.

I can't remember offhand what the thread size/pitch is, but I've done this repair on several modular motors (the 4.6/5.4/6.8 are all affected by this crap). A good high quality stainless bolt will fix the problem permanently.

1. Use OEM gaskets
2. Use anti-sieze (stainless + aluminum can = seized bolts)
3. Good luck getting the old studs out!

 

Are the 6.2 having this problem?

 

I'm appreciating the input. Between this thread and my searches on other threads I'm seeing conflicting and varied advice on this broken stud issue. There seems to be a lack of reports as to how long each repair lasted so it's very difficult to sort out.

So what I would like to hear is what kind of fix was done on your truck and how many actual trouble free miles (no more broken studs or leaks) have you had after the repair?

 

I also would like to know,one of the studs just broke yesterday on my 99 f250/5.4 its really upsetting

 

The thread size is 8mm 1.25

Here is a recent thread I made with pictures. I replaced broken manifolds with gibson headers.

https://www.ford-trucks.com/forums/1...ticipated.html

Its a big project. Your aluminum head will start to corrode if you leave it alone for too long.