I posted this in the 5.4L forum, but no luck. Maybe someone here can help me. My '00 X-pe EB has a broken exhaust stud on the right rear. Supposedly there's a Ford service bulletin on this for the F-150's. The dealer wants $500+ to do this and I just don't want to pay that for 1 bolt! I want to fix it myself.

Has anyone else gone through this? Any tips on the best way to fix it, links to fixing it or the service bulletin, tools to use, etc. would be much appreciated. Thanks, Dave

 

How did it break? Were you removing the manifold? How much is sticking out? If any is sticking out, and the manifold is off, heat the stud up very hot and touch a candle (no kidding) to it and hold it threre. Let cool. Grab protruding piece with vise grips and it shoud break free and come on out. The wax from the candle will migrate down the hot threads much like solder cappilates up into a copper pipe joint. Once in there, it acts as a very good lubricant. If there is nothing sticking out, still do the "Candle Trick". then a high quality easy out-but I don't know if you can even get to it with a drill back there. Lastly, try getting a bolt welded to the stud piece, do the candle trick while its hot, and you should be able to turn it out. All would be WAY more easy if the engine was out and sitting on a stand, but sometimes we gotta play the cards dealt to us! Hope this helps. Keep us posted!

 

Easiest way is to remove the manifold and replace all the studs and nuts with new ones. It's not that difficult to do. remove the rh wheel and inner fender well, disconnect the exhaust at the flange, remove the rest of the remaining nuts to the manifold and remove it. Most times you can get ahold of the stud and remove it with a visegrips, occationally you do have to drill them out. Use a left hand drill bit and the come right out. Replace the gasket and studs, install the manifold and wheel well and wheel and your done.

 

Thanks for the tips guys. And, the thing rusted and broke off by itself, which seems premature for it only being 4yrs old w/96K miles. Luckily it broke off flush w/ the manifold, so after removing it I should have a piece to grab. The other studs are so rusty that its hard to distinguish them from the nuts, so you all may want to check yours also.

1. So if I take the manifold I should be able to get the stud out with vise grips? I don't want to break it off more at the head.

2. Anyone know how the Ford dealers do it, or know what the service bulletin on this for the F-150 (? King Ranch) says about the rusty studs?

 

I work for ford. That's how I do it. And yes, it will usually come right out with a visegrips. It's usually not that bad of a job to do, good luck, and have fun!!!

 

Thanks Ranger88a! That gives me more confidence to do it myself. My years of working on my own cars will not let me spend $500 to get one broken bolt taken out. As for the fun, well we shall see ...Thanks again!

 

No problem, have fun.

 

Hey y'all just wanted to say a major THANK YOU for saving me at least $400! I did the job yesterday and it was done in an afternoon no problem. Turned out both the upper and lower exhaust studs on the rear were broken off, but after I got the manifold off they came right out with vice grips. All back together and running hard as h*ll again! I love this forum, and all the great advice & info out there.