I have a loud ticking noise at all engine rpm ranges. It sounds like an exhaust leak but I haven't checked good enough yet. This truck only has 60K miles on it and is a 97' 4.6L. Do these engines have problems with spark plugs like the 5.4's? Reason I ask is because I wonder if that ticking is coming from a bad plug or something. It doesn't seem to have alot of power either. It sounds like an old beat up carbeurated truck when you accelerate with this ticking noise.

 

It's most likely an exhaust leak. My truck is HORRIBLE. The multiple exhaust leaks actually drowns out my Flowmaster Super 40 AND my 12" subwoofer.

 

Most likely you have 1 or more broken exhaust manifold studs.

 

is it hard to fix this problem? what do I need to do? I'm very mechanically inclined...I just need to get rid of this tick!

 

Its not hard. All you gotta do is take off the tire, take off the splash guard to access the exhaust manifold, take off the manifold and remove the broken studs.
Sometimes they can be a real pain to get out. I was lucky, on mine we just used a pair of Vise Grips and got them out, but Ive heard of some people having to use a torch to get their's out.
If you are very mechanically inclined you should be able to do it no problem. Im not much of a mechanic and it wasnt too bad, so for you it should be a piece of cake.

 

Did the factory use exhaust manifold gaskets? Also where should I get replacement studs?

 

Just had both manifold replaced on my '97 4.6. Local Ford stealership wanted $ 1,300 I went with a private garage they did it fot $ 830.00. They told me the Ford manifolds are expensive and the same any other makes. I only have 72,000 miles on it.

 

Yes there are gaskets between the cylinder head and the manifold. The dealer sells replacement studs that are stainless steel to correct the problem od rusted and broken studs.

 

Holy cow...why did you replace the entire manifolds? Did they crack on you or something? I think the studs are in question here which would be alot cheaper. Gaskets aren't much either.

 

Yeah, the studs are a heck of a lot cheaper than that. I replaced 3 studs in mine and I think it cost me less than $20.
Also, yes they did use gaskets from the factory and yes you should replace them. I just bought a set of gaskets from CarQuest and I think they cost me less than $5.

 

The Ford stealership said they were rusted out (had holes in both manifolds). I'm not sure as I didn't see them, but the garage I used replaced both of them.

 

This seems to be a common problem. My brother had the same issue in his 01 with 120k on it. To make a long story short, he hacked the head so badly trying to get the stud out that I couldn't even get a helicoil to work. I ended up having to replace the head just so we could take care of an exhaust leak...ridiculous.

Anyway, I am interested in a permanent fix on this as it wasn't a lot of fun to fix the first time around (we're the type to drive our vehicles into the ground) and don't intend on doing it again. When I reinstalled the manifold the y-pipe seemed to want to pry the manifold away from the head which would over time fatigue the stud to failure. Has anyone adjusted (BFH) their y-pipe to make up for this misalignment?

 

Well since this thread was resurrected, I'm actually trying to get my driver side manifold off right now. Sure enough that thing has a huge hole in it right by the EGR tube. The studs and nuts actually haven't broken to my surprise but they are so rusted. I can't get one of the top nuts off and all 4 bottom. They are very hard to get to. I'm not sure what I am going to do. I guess my dad said there's some sort of tool that splits the nuts in half or something. I tried torching them off but the torch does nothing to these things (its a small propane torch). Even the bolts that hold the exhaust to the manifold are crap and a pain to get off. Talk about a nightmare job!

 

Every exhaust job falls under this category in my opinion.

Don't get impatient with the rusted nuts....take your time and soak it in penetrant many times before you even try to get them off. If it comes to it, a nut splitter may work but I think they are mostly designed for larger sizes...here is an example: http://www.sears.com/sr/javasr/produ...seBVCookie=Yes
It may be tempting but going at them with an impact will snap the studs very quickly so avoid doing this.

Just curious but where was the hole on your manifold? On top of the studs being broken, the manifold had a deep crack between cylinders 5 & 7.

 

the hole is right on top right next to the egr tube fitting