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I thought all was fine with my 01 F250 V10. I bought it used with 110K miles. Truck seems to run well, but read a lot about broken exhaust studs and checked mine. Guess what, textbook two rear passenger side bolts broke. One of the studs is broken flush with the head and one flush with the manifold. I don't want to cause a problem where there isn't one, but I think I can probably fix it without removing the manifold. I shoould be able to use an easy out or just drill them out using the manifold as a guide hole.
I just got Thorley headers installed on my 04' w/ 27k before any studs were broke. When the shop put the headers on they found one of the studs was indeed busted off below the manifold flange.
I would definatly change all the studs because they will break. Its sort of a pay me now or pay me later type deal.
IMO a well maint. 04' like mine w/ 27k should not have any broken studs, but what do you do.
Ford originally used steel studsfrom what I have read here. Make sure you get stainless one to replace them. The Ford garage may try to sell steel ones.
I pulled both my 99 F53 manifolds, had total of 7 out of 20 studs broken flush with the head. I put on a Banks system rather then reinstall the stock manifolds. Big difference in heat dissapation, fan clutch never engages now.
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