2003 V10 Exhaust Headers
Junior User
Joined: May 2008
Posts: 65
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From: WV
I used Ford motorsport headers on my v10 the bolts it used a dremel tool with a cutting disc. I cut the nuts off it is a PIA to say the least. The motor mounts I ended up cutting the exhaust manifold in half. This left the studs exposed with the manifold off. I bought two stud removal tools and they worked perfect. I had 4 broken at the rear of the motor. I would change them out ASAP before the studs break, to prevent problems. It was the worse job I had ever done on a vehicle. I cut the inner fender well partially out removed the starter and the front shocks and mounts for clearance. I also collapsed the steering column on the drivers side.
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Elder User
Joined: Apr 2010
Posts: 619
Likes: 6
From: Steeler Country
We used a lift so going up or down to get a bolt wasn't so bad. Also removed inner wheel well, shock and tower. Never took out steering rod, told to be careful if you do. If Steering wheel is not locked then it could spin when shaft comes out causing air bag to deploy. With broken studs left we used the cam style remover. Looks like a spark plug socket with some black piece inside which grabs it. If broken off at head, left hand drill bits on a air drill which was a 90 degree job, thin head and chuck. Then after drilling about 1/4 into the stud, we used an extractor bit to grab and pull them out. This was done by hand. Work them back and forth once broke free, some PB Blaster and they came out. We did heat everything before trying to get out, except when we drilled and used extractor.
Posting Guru
Joined: Apr 2010
Posts: 1,112
Likes: 0
From: South Shore, MA
i am doing a header conversion as well right now. i had a total of 10 broken studs befor and thats the reason for the headers. i am having a hell of a time getting the studs and ive tried every trick i could find in the search function. dam this is a sucky job. how do you guys get to the bolts by the motor mounts?
https://www.ford-trucks.com/forums/9...s-weekend.html
Junior User
Joined: Apr 2010
Posts: 66
Likes: 0
If you have access to a MIG welder, it could end up being your best friend. Check out the process I used for mine - just a few weeks ago...
https://www.ford-trucks.com/forums/9...s-weekend.html
https://www.ford-trucks.com/forums/9...s-weekend.html
i have a mig welder and welded on rod coupling nuts and still nothing. how much can you heat an aluminum head with a tourch befor bad things happen
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