broken exhaust studs
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Tuned
Joined: Sep 2006
Posts: 259
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broken exhaust studs
Hi i i have an 06 f250 sc 5.4l with 20,000 miles. i noticed recently while towing my boat that there was a ticking noise coming from the front of the truck.As i drove on with a load on the truck the noise becomes louder and now over a 3 month period is getting worse.Since i have a few weeks left under my 3/36k warranty i brought it in to the dealer to learn that the exhaust manifold bolts on the passenger side are broken and the manifold is leaking .When i asked the dealer if they have a fix,such as stainless studs, he said no they just replace with what ford gives them and that the problem will return eventually. My question is I thought they resolved this issue on the newer models,after 04. I asked if i got stainless studs if they would install and he said yes.Does any one know where i can get stainless exhaust manifold studs, And would this help stop the rotting problem of the stock studs or are they not worth the money. Thanks
Former ******
Joined: Nov 2004
Posts: 4,901
Likes: 2
From: Salt Lake City, Utah
They are right, use the ones Ford give you. The problem with the stainless studs is galvanic welding. Plus stainless is not entirely corrosion proof, especially at those temperatures. When you use the stainless studs, they permanently weld together, making them almost impossible to remove. And you can't cut them with a standard torch.
I would say its not worth the money to get stainless studs. If you do, be very specific about the type of stainless. Make certain it is marine grade stainless, anything else will still rot, it just takes longer than standard steel.
I would say its not worth the money to get stainless studs. If you do, be very specific about the type of stainless. Make certain it is marine grade stainless, anything else will still rot, it just takes longer than standard steel.
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Tuned
Joined: Sep 2006
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well that answers the stainless question but what about the issue that it happened on a truck that has been in service for not even 3 years?..I understand that the low miles mean that it sits more than it is driven but it has stayed sheltered till recently.Its just a shame y yet oh well thanks
Elder User
Joined: May 2008
Posts: 574
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From: SW Idaho
I think the bolts fail because of their poor quality not external rust. They become brittle from the heat/ cool cycling and break.
note... I stand corrected: (there are some grades of stainless steel bolts than can be used on exhaust manifolds)
note... I stand corrected: (there are some grades of stainless steel bolts than can be used on exhaust manifolds)
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Tuned
Joined: Sep 2006
Posts: 259
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well i just got my truck back from the dealer and its nice and quiet now.They told me that that the exhaust manifold gasket had warped and wasnt sealed, so they replaced the passenger side gasket plus the bolts and a couple other parts listed on the invioce.I dont get how a gasket warps thats bolted between two parts but shes fixed i guess and im happy.What also gets me is that i was told this was a comon problem on the passenger side but yet i dont believe i heard anyone else have this problem.
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More Turbo
Joined: Aug 2002
Posts: 537
Likes: 17
From: Linden USA
Maybe the manifold was warped, and they replaced that. Not sure, but does Ford even use a exhaust manifold gasket from the factory? I know the older ones did not have a gasket.
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Brett Foote
Senior User
Joined: Oct 2005
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From: NW NJ
Thats what happened with my '02 ..... some studs failed and the manifold warped. I *believe* the studs I got from Ford with the manifold were stainless with some sort of unreactive outer coating/treating.
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
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From: Long Island USA
The stock studs are stainless.
They either fail at the shoulder (bad heat treatment) or down in the threads.
The problem is related to the manifold expanding and contracting, and the original nuts rot and stick to the manifold. The manifold expands and contracts, it drags the nut with it, and eventually fatigue the stud.
My '01 V10 had sheet-metal gaskets.
I think the copper plating on the nuts is to try to keep them moving in relation to the manifold, but that's just a theory.
They either fail at the shoulder (bad heat treatment) or down in the threads.
The problem is related to the manifold expanding and contracting, and the original nuts rot and stick to the manifold. The manifold expands and contracts, it drags the nut with it, and eventually fatigue the stud.
My '01 V10 had sheet-metal gaskets.
I think the copper plating on the nuts is to try to keep them moving in relation to the manifold, but that's just a theory.
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