manifold bolts AGAIN!!!
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Junior User
Joined: Jul 2006
Posts: 97
Likes: 0
manifold bolts AGAIN!!!
Well, I got my Truck back from my plow guy the other day and The exhaust noise is back. I looked and the front bolt is missing after only 2 years UGH!! Last time they were almost all broke. Even better the Dual Exhaust (Flowmaster) Fell off and WOW, what a racket that makes. 
Rant over!
Rant over!
Lead Driver
Joined: Sep 2003
Posts: 5,844
Likes: 6
From: Albuquerque
Maybe?
biz
Senior User
Joined: Jul 2006
Posts: 268
Likes: 1
My '99 is still in the shop having these replaced for the first time. I agree that part of the problem is the size of the stud. I think that the design of the manifolds also contributes to the problem. I was deluding myself (apparently) into thinking that I wouldn't have to ever do this again. Out of 20 studs, 6 came out in one piece. 4 came out without drilling and 10 had to be drilled and helicoiled. Of course it was the hard to get to ones that needed the drill. I am hoping that the use of antisieze (which Ford didn't use) the coorect alloy studs from Ford, and the helicoils will make this horrible job easier if I have to do it again. I am very glad I didn't decide to do this job myself in my driveway as I'd probably had to have added a tow bill to the expense of the work.
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FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 423
From: Long Island USA
Big long manifold, it expands when it heats up, and contracts when it cools off.
The nuts weld (rust) themselves to the manifold, so the manifold drags the nuts with it when it expands and contracts. Result? Broken stud.
With the Ford FE's (360/390/428/etc), it would crack the manifold instead
The nuts weld (rust) themselves to the manifold, so the manifold drags the nuts with it when it expands and contracts. Result? Broken stud.
With the Ford FE's (360/390/428/etc), it would crack the manifold instead
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Mountain Pass
Joined: Nov 2005
Posts: 239
Likes: 9
From: moreno valley calif
could it be the climate where the vehicle is used? all my manifold studs are fine..im going off memory, but i dont think the nuts are rusted..just the studs..but they are all present and accounted for.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
Manifolds are stainless on the V10. The studs on the majority of V10s are a mild magnetic (Heat treatable) stainless. In general stainless bolts are soft and will shear or snap off quicker than a Gr5 or Gr8 bolt. The stainless manifolds will usually expand more when heated than cast iron.
Senior User
Joined: Jul 2006
Posts: 268
Likes: 1
Manifolds are stainless on the V10. The studs on the majority of V10s are a mild magnetic (Heat treatable) stainless. In general stainless bolts are soft and will shear or snap off quicker than a Gr5 or Gr8 bolt. The stainless manifolds will usually expand more when heated than cast iron.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
Ford might have gone to stainless in later years but on my '99 the exhaust manifolds are not stainless. I think they are cast iron but they are considerably lighter than cast iron manifolds that I am familiar with. The shop sent them out to machine a flat edge on the manifolds so the new gaskets would seal better. They look very nice.
Very well could be cast iron in 99', I don't know for shure. It usually takes Ford about 2 years after a complete redesign to get the little bugs worked out and they figure out what parts they are going to use in the long haul. When my dad bought his shiny new 99' he was pretty pissed in 2000 when Ford upped the power to 310 on the 6.8l.
Just to put it out there, the stainless manifolds will rust and will look like crap after many years of use. They don't use a 300 series stainless on the manifolds.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
See if you can find a reputable small garage in your area to replace them. The local shop charges $50 an hour, but your lucky to find a dealership at $90 an hour. My dad got all studs replaced (6 broken) for under $500 at a local garage.
Posting Guru
Joined: Apr 2003
Posts: 1,089
Likes: 1
From: Michigan
Yea, I'm going to start calling around.