Had the pleasure of finally getting around to fixing the broken bolt on my buddies truck. Quick recap. While installing an EGR delete, I broke one of the bolts off on the exhaust manifold where the EGR tube connects.



After trying numerous things to get the broke bolt out, I got fed up and ordered a new exhaust manifold ($30 from Autonation Ford).

Removal wasn't too terrible. Toughest part was getting the 3 band clamps to let go for the up pipes and down pipe.

Tip 1: Completely take the downpipe off the truck. This is accomplished my removing the passenger side wheel well liner. I also removed the tire for complete access to everything behind the engine. If you have ever owned a 6.0 or 6.4, this will put a smile on your face as it comes out very easy in one piece WITHOUT cutting it.

Physically snaking the turbo out was a tad challenging. Once you get it up a little, start coming forward then rotate it counterclockwise wise as you are coming up and forward.

Tip 2: My project consisted of replacing the passenger side exhaust manifold. If you find yourself in this situation, make sure to order the three studs that secure the up pipe to the manilfold. I assumed they came with the new manifold but that wasn't the case. After fighting the broken bolt, I had no desire to fight the three studs in the old manifold.

Assembly was made easy thanks to the downpipe being out of the way. This makes access to the driver side up pipe clamp a breeze.

Tip 3: After fighting to get the turbo back in and really not wanting to mess the gasket up, I decided to remove the wastegate off the charger. It went in extremely easy. I highly recommend this. Save yourself some swearing.

All in all, it wasn't terrible. Nowhere near as easy as a 6.0 turbo swap and (me personally) easier than a 6.4 swap. Total time was about 5 hours. This was my first time going that deep into a 6.7. I feel much better about future projects for my own truck now. This may already be common knowledge to most, but after doing a good bit of reading and watching, these are some things I wish I would have known going into it. Hopefully it will make someone's day a little easier.

Tip 4: Pick a sunny day to accomplish this task.















P.S
This wouldn't be a complete thread without some mention of a sensor failure from the exhaust. He uses an SCT x4, so I figured I would use my DashDaq to watch his vitals. I would say this exhaust sensor would have put him on the side of the road! Reckon the EGTs at idle are a tad warm?

 

Great thread and some good tips.

 

Great write up and pics. Thanks!

 

I guess he is using the sctx4 to accommodate the delete...What program kem or pip?

 

I believe PIP. Not overly impressed with the tuning. Injector rattle is awful.

 

Double post

 

UGA33 - I know this is a real old post but I am getting turbo codes so time to pull and replace. Right now I have the EGR block off plate. Would deleting the whole EGR system make pulling the turbo easier?

 

Personally, I think it would. Not much easier, but I'm on the large side and love having all the free space I can get. It helps with the up pipe and downpipe clamp removal.

 

Thanks. I'm researching cab removal right now. I have a lift so if I don't have to tear too much apart the cab lift may be easiest.

 

Once off, it would be easy. I don't think it's so bad that I would consider lifting the cab though. 6.7 cab removal is pretty easy though.

 

on the 3 studs u mentioned to make sure and order which ones are they? I just ran into the exact same issue and have tried everything to remove the bolt but no luck next option is now replacing passenger side exhaust manifold. Where the rest of the bolts a pain to remove as well?