broken V10 exhaust studs - Ford Truck Enthusiasts Forums

Notices
Modular V10 (6.8l)  
Sponsored by:
Sponsored by:

broken V10 exhaust studs

Reply

 
 
 
  #1  
Old 02-05-2008, 12:36 PM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
Question broken V10 exhaust studs

greetings, new member here. there is a TON of good info on this site. the bad thing is, most of it will end up costing me money.

i took my 2002 F350 V10 in for inspection today and the garage told me a bunch of the exhaust manifold studs are broken off at the head. being cheap (and not having $1000 laying around) i want to attempt this repair myself. i've rebuilt cars, motorcycles, farm tractors, etc. so i'm not a novice mechanic, but i have never worked on a V10. how big of a pain in the butt is it to get at these studs? i'm guessing i will need to drill some of them out. are there any other tips anyone has to offer me? should i replace all of them while i'm in there? any guidance, tips or photos are appreciated.

thanks,

andy b.
 
Reply With Quote
  #2  
Old 02-05-2008, 02:47 PM
dkf's Avatar
dkf
dkf is offline
Post Fiend
Join Date: Mar 2007
Location: Pa
Posts: 10,095
dkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to behold
Heres a link to a thread with some pics and info.

https://www.ford-trucks.com/forums/5...ghlight=header

You will have to remove the front inner fender liner to get to the studs for the best acces. When I got my headers on the mechanic didn't remove the fender liners though, which amazed me I don't know how he could get in there. He was a thin little guy though.

If the studs are broken off flush with the head or below the head surface obviously removing them will be harder. An easy out or drilling the studs out completly may be what you need to do to get them out. The studs can be hard to drill or will work harden (SS studs) when your drilling them out, use cutting oil or a water soluable cutting fluid to prevent work hardening. If the stud sticks up above the head you may be able to work it out with a vise grip. The studs usually don't turn out hard.
 
Reply With Quote
  #3  
Old 02-05-2008, 08:35 PM
rich250
rich250 is offline
Senior User
Join Date: Nov 2007
Posts: 189
rich250 is starting off with a positive reputation.
if your mechanically inclined it won't be a problem,just time consuming,I recently done mine,replaced the manifold gaskets with fel pro gaskets,replaced the studs with grade 8 bolts and plenty of nickel antisieze.
 
Reply With Quote
  #4  
Old 02-05-2008, 09:03 PM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
thanks guys!!!! and DKF, that was EXACTLY the type of thread i tried searching for. it sounds like it will be a little of a pain, but nothing i can't handle. i may have to get some new drill bits though if these studs are stainless. heck, any excuse to buy more tools is a good one though.

i'm going to start this project friday, so i'll post back on the weekend how it goes.

thanks again.

andy b.
 
Reply With Quote
  #5  
Old 02-06-2008, 07:58 AM
dkf's Avatar
dkf
dkf is offline
Post Fiend
Join Date: Mar 2007
Location: Pa
Posts: 10,095
dkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to behold
You may want to pick up a center drill or drill/countersink like pictured below.


You can center punch the stud and use the center drill to start the hole. I use them all the time and they help keep the drill from wandering.

A cobalt drill bit will hold up to the stainless better. You can either resharpen the bits by hand or use a drill doctor. I've been using a drill doctor for several years and it works well for re-sharpening bits. I also use it on solid carbide drills to.

Good luck with your project.
 
Reply With Quote
  #6  
Old 02-10-2008, 08:47 AM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
well i started friday morning at 8AM and ended saturday night at 8PM. it actually went VERY smooth except for one stud on each side. one i had to drill out, and one the nut would not come loose and i had to chisel it off (of course, that nut had to be on the bottom of the middle cylinder ). 8 studs were broken off and 2 or 3 others looked like they probably wouldn't last much longer. the truck is noticeably quieter in the cab.

cost for parts $185
cost for tools $130, but at least i have new tools to use for other projects

thanks for the tips, they all came in handy!

i guess the next project i'll have is spark plug replacement, but with only 60k miles i'll wait a bit longer.

andy b.
 
Reply With Quote
  #7  
Old 02-11-2008, 09:07 AM
dkf's Avatar
dkf
dkf is offline
Post Fiend
Join Date: Mar 2007
Location: Pa
Posts: 10,095
dkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to behold
Originally Posted by andy b.
well i started friday morning at 8AM and ended saturday night at 8PM. it actually went VERY smooth except for one stud on each side. one i had to drill out, and one the nut would not come loose and i had to chisel it off (of course, that nut had to be on the bottom of the middle cylinder ). 8 studs were broken off and 2 or 3 others looked like they probably wouldn't last much longer. the truck is noticeably quieter in the cab.

cost for parts $185
cost for tools $130, but at least i have new tools to use for other projects

thanks for the tips, they all came in handy!

i guess the next project i'll have is spark plug replacement, but with only 60k miles i'll wait a bit longer.

andy b.
You might want to replace the plugs ASAP. My dads 03' started getting a missfire when cold at about 65k. We replaced the plugs and boots and the missfire went away. The modular motors come from the factory with single platinum plugs, but they wear fast and everyone here agrees 50k is about the max to get out of a set. The V10 runs best on the single platinum Autolite or Motorcraft plugs.
 
Reply With Quote
  #8  
Old 02-11-2008, 04:25 PM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
dkf,

thanks for the tip! i guess i will gather up the parts (new plugs and boots) and give it a go when it gets a little warmer out.

oh, i took the truck to work today and i definitely noticed it was quieter out on the highway. i think it's back to where the tires are louder than anything else (well, except the radio ).

andy b.
 
Reply With Quote
  #9  
Old 02-11-2008, 06:43 PM
dkf's Avatar
dkf
dkf is offline
Post Fiend
Join Date: Mar 2007
Location: Pa
Posts: 10,095
dkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to beholddkf is a splendid one to behold
Yeah an exhaust leak at the manifolds can really make noise.

When I got my headers on the gasket got cracked and leaked. It was one little leak but made alot of noise. It sucks spending over a grand for a set of headers and not being able to test them out because your waiting for a new gasket.

My dads 6.8l had 5 broken studs, but no leaks. I had 28k on my truck when I got the headers on and the shop said I had one broken stud.
 
Reply With Quote
  #10  
Old 02-16-2008, 08:59 AM
lariat79sc's Avatar
lariat79sc
lariat79sc is offline
Elder User
Join Date: Jun 2005
Location: Darien
Posts: 547
lariat79sc is starting off with a positive reputation.
If your lucky most haven't broke off so deep you can't get a vise grip on them. I had only 2 deep ones on the p/s to extract.
 
Reply With Quote
  #11  
Old 07-13-2017, 04:19 PM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
I don't frequent this forum, obviously, but it IS a good reference for issues related to my 2002 F350. I still have the truck (since new) and I was going back over old links for....
you guessed it, broken manifold studs. LOL!!!
I replaced all of them on the passenger side yesterday. Five were broken off. Only one is broken on the driver's side, so I left it alone for now.
The repair back in '08 was with factory hardware from Ford. That was about 60k miles ago (I'm at 111k now).
Anyway, just thought I'd post a long-term update, if anyone cares.

Andy B.
 
Reply With Quote
  #12  
Old 07-13-2017, 06:29 PM
z31freakify's Avatar
z31freakify
z31freakify is offline
Post Fiend
Join Date: Dec 2012
Location: Las Cruces New Mexico
Posts: 5,830
z31freakify is a splendid one to beholdz31freakify is a splendid one to beholdz31freakify is a splendid one to beholdz31freakify is a splendid one to beholdz31freakify is a splendid one to beholdz31freakify is a splendid one to behold
WOW!!! 9 year update, Sweet thanks for replying back Andy,
 
Reply With Quote
  #13  
Old 07-13-2017, 10:37 PM
andy b.
andy b. is offline
New User
Thread Starter
Join Date: Feb 2008
Posts: 6
andy b. is starting off with a positive reputation.
z31,

I don't know if you were being serious or sarcastic, but it is pretty funny for me to reply to a 9-year-old thread.

But hey, if anyone was wondering, it gives another data point on the exhaust stud issue. LOL

Andy B.
 
Reply With Quote
 
 
 
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
MarylandExcursion
Excursion - King of SUVs
10
01-31-2018 06:58 AM
CourageDaCowardlyDog
Alternative Fuels, Hybrids & Mileage
1
10-03-2017 08:47 AM
bsraborn
Small Block V8 (221, 260, 289, 5.0/302, 5.8/351W)
13
06-09-2017 04:35 PM
2,4shofast
1999 to 2016 Super Duty
1
05-03-2017 02:59 PM
Lance Helmert
Excursion - King of SUVs
40
01-25-2017 09:36 AM


Thread Tools
Search this Thread
Quick Reply: broken V10 exhaust studs


Contact Us Archive Advertising Cookie Policy Privacy Statement Terms of Service

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.