Recently both left and right front exhaust studs have broken off of my 6.8L 3V. I'm not sure for the reason as driving conditions and engine temp are and have always been steady. Has anyone else had this same issue? Ford wont warranty the stud replacement as the tech said the manifolds are warped but that is a tough sell to me. I'm not about to drop $2k for new manifolds and studs to fix two snapped studs. Any idea of why or what might have caused this? Thank you in advance!

 

There probably isn't a single 6.8l Triton engine out there that does NOT have exhaust manifold stud breakage. Design flaw. Do a search on this site about it and you will read until your eyes bleed about repair/replacement suggestions and methods.