ok guys, im getting ready to remove the passenger side header from my 1997 5.4. I have read a lot of different "tricks", but what works best for you guys. all I have done so far is put some naval jelly on the bolts to try and remove some of the rust. has anyone ever used "freeze off"? thanks for any help you all can give me.

 

I guess I would hose em down with some PB or Kroll. Do that for a few cycles and try a few. Last thing you want is a broken stud. Don't get too carried away when taking them off. Probably need to take the wheel off as well as the inner fender to get better access. Good luck.

 

I'm in the same boat. My factory headers are rusted away and I want to replace with a set of shortys (since they should line up with factory exhaust so I'm told).

The videos I've seen have you just soak the studs with oil, apply heat, and turn out. If they break I've seen them notched with a dremel and use a screwdriver, or flatten and vise-grips. Don't remember anyone breaking one in a video in the block, but if the stud does break with some thread exposed then you can remove the header and work with the stud that's sticking out.