Ok gang, here's the deal. I'm working on a 1990 F-150 4X4 with a 302, or 5.0L. I am doing a head gasket job and have run into a few issues with broken bolts along the way. The major problem I have left to solve is with the intake bolts. One right rearmost bolt/stud snapped off and I am trying to figure out how to replace it. It seems a couple other bolts are a little corroded around the same area of the stem so I don't even want to re-use those because I am sure they wouldn't handle being torqued.

The problem now being no one that I can find sells replacement bolts, and it sounds like the dealership only sells them individually. I am just wondering if anyone else has run into this problem and what you did about solving it. I am going to call the dealer back because they wanted specific stud measurements which I couldn't give them at the time. If I have to buy the bolts individually then so be it, if that's the best route to go.

Another issue I am having is the location. I thought I was careful enough to keep the bolts in the same order they came out. But I have a stud, which seems identical to the one that broke off, that appears to be out of place. Every manual I look at isn't much help as far as the locations. Could someone possibly look at there truck and see where that other stud is located for me. I know they were there for a reason whether it held a ground or whatever. Or maybe one of you remembers where it goes from memory. I'll tell you where I have it now. I have it located in my template as the second to the rear on the right side, so it is the next one forward of the one that broke off. Everything else seems to be in order. For some reason I thought the other stud went to the rearmost position on the left side. I have the two studs that hold the coil and stuff in the right place.

Thanks ahead of time guys. I know I am asking a lot here.

 

I just rebuilt my 87 F-350, 460 and had to replace some bolts. The local Ace Hardware had the harden stud bolts in special bins. I also broke off exhaust bolts in the heads, took the heads for a valve job and they also removed the broken bolts for very little cost. Ace also had the hardened bolts for the exhaust manifold, intake and exhaust studs from header to exhaust pipe connections. The arent cheap! But cheaper than Ford.

 

You can use any bolt of the right size and thread as a replacement, the intake only sees a light TQ load you don't need grade 8 or anything though better quality bolts will better resist corrosion and breakage with age. The studs could be a problem though as most hardware stores don't carry this type fastener so you may have to go to the dealer.

 

Can you post a picture of the stud you need to replace as I have a couple different complete EFI engines in the barn and a few bags of extra parts from stuff over the years. Last intake I bought a ARP bolt kit for the Machine Shop that did the block work for me. Or you can use Grade 5 bolt from hardware / Granger / McMaster Carr or ?? Use At least a Grade 5 or better. Grade 2 is very soft and easy to snap off, Grade 8 is over kill but will work.

 

Evo, I'll try the local hardware store, thanks for the tip there. I am usually surprised by what they have.

As far as the bolts, yeah, any that needed replacement I will go to the hardware store for sure for those.

The only exhaust manifold issue I have if I broke stud off in the left side. But the manifold itself is fine. Of course everything on the passenger side came out ok, but that manifold is ready to crumble into about 4 pieces.

 

As much as appreciate this offer I am scrambling to try and get this truck together and out the door before I head out of state for a few days. If there is no chance I will get it done by then, I will get you a pic of the stud. I am going to try the hardware store as well to see If there is something that will work.