removing manifold for pyro?
Cargo Master
Joined: Jun 2003
Posts: 2,203
Likes: 0
From: Carlsbad, California
I took mine off. Not too bad of a job. I jacked up the truck and removed the left front tire to give better access.
The only tough part was getting to the two bolts that bolt the manifold to the riser pipe to the turbo. I'd unbolt them first then go for the manifold. The edge of the heat blanket has an aluminum foil on it that cuts into the back of your hand as you're trying to reach the nut on the back side of the bolt and that was a pain.
The manifold itself just has the 8 bolts - 10 mm if I recall and a sensor tap in the front. The manifold bolts are torqued pretty light so they came right out.
There is no gasket, at least none on my '03.
I drilled and tapped the flat spot that is near the rear most cylinder port. A lot of guys have done the drill and tap with the manifold on the truck but I felt better doing off the truck - especially once I saw all the chips that the procedure produced. Though most of the chips would have fallen to the outside during the drilling operation.
Some have even done the drill/tap procedure with the engine running to produce some positive pressure and blow any chips back out.
The only tough part was getting to the two bolts that bolt the manifold to the riser pipe to the turbo. I'd unbolt them first then go for the manifold. The edge of the heat blanket has an aluminum foil on it that cuts into the back of your hand as you're trying to reach the nut on the back side of the bolt and that was a pain.
The manifold itself just has the 8 bolts - 10 mm if I recall and a sensor tap in the front. The manifold bolts are torqued pretty light so they came right out.
There is no gasket, at least none on my '03.
I drilled and tapped the flat spot that is near the rear most cylinder port. A lot of guys have done the drill and tap with the manifold on the truck but I felt better doing off the truck - especially once I saw all the chips that the procedure produced. Though most of the chips would have fallen to the outside during the drilling operation.
Some have even done the drill/tap procedure with the engine running to produce some positive pressure and blow any chips back out.
Cargo Master
Joined: Jun 2003
Posts: 2,203
Likes: 0
From: Carlsbad, California
Here's a link to a thread regarding pre vs. post turbo installation and more of a writeup on how my install went.
https://www.ford-trucks.com/forums/s...d.php?t=218539
https://www.ford-trucks.com/forums/s...d.php?t=218539
Senior User
Joined: Oct 2003
Posts: 244
Likes: 0
From: Florida
I put grease on drill bit and stuck a magnet in the hole. Did it to my old truck put 100k on it and did it to my new truck got 15k on it. No problems. Removing maniflod seems like an awful lot of work just to drill a small hole. But guess if you want to be extra cautious go for it.
Mountain Pass
Joined: Feb 2004
Posts: 121
Likes: 0
If you do the passanger side header it has very easy access to it. There was pleny of room to get my drill in there. I just started with a small bit and worked my way up. Everytime using a shop vac and some grease(esp when taping) I wouldn't waste the time to take off the manifold, just take your time and you'll be fine.
