Found the exhaust leak on my 1994 F350, 5.8L. The number one cylinder has a broken exhaust manifold bolt. Is there a history of manifold bolts breaking on this engine, or is it likely the previous owner attempted to fix a leak and broke the bolt?

I assume the latter, but I have heard other truck engines have had this issue.

 

i have had an exhaust tick since the day i bought my '94 5.8.
decided the other day that i would put a wrench on the front-most, upper-most bolt. it started moving right away, so i thought it was loose, when, in fact, it was shearing off with incredible ease.
it will stay sheared off now until such time as i pull the engine for some other reason.

 

Was it the first bolt on the passenger side? That's the one broken on mine.

 

yes. that's the one.

 

I have a 96 5.8L and have not had any issues yet with 158K miles on it and hope I never do.

Rusted broke exhaust bolts are a royal pain to deal with, been there before.

 

I had the exact problem. I found mine broken off after I started tearing into other things on the truck. If you do a search on my name, you'll find a few threads where I got it out.

Not fun, but I was able to remove it.

 

I use opportunities like these as excuses to upgrade. Ditch the e7 heads, add a cam, install long tubes would be on the list.

 

It really does need an upgrade.

With 285's, 3.55 gearing and a C6, it's pretty sluggish. If I keep the truck, I'd like up upgrade to 265's, 4.10, 7.5L, and a ZF5. I have a parts truck that has everything except the ZF5, clutch pedals and manual transmission computer.

I just wish there was as much aftermarket support for the 7.5 as there is for the 5.8. Then the decision would be easier. Still, I think I'd be further ahead going with a big block over building up the small block. Of course, I could be wrong?