Exhaust manifold replacement gone wrong

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Jun 6, 2010 | 06:21 PM

KWest

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Exhaust manifold replacement gone wrong

I have an 01 F250 with the 5.4. Yesterday I attempted to replace the passenger side manifold and rusted studs. Since there was no real shape left to the nut I torched them off to get the manifold off. Once it was off I tried heating the head and using vise grips on the studs. I got 3 out, and one was broken when I pulled the manifold. it had been for a while judging by the rust. While trying to drill out a stubborn stud I drilled to far and into the water jacket.

What should I do now?

Jun 6, 2010 | 06:34 PM

gearloose1

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I have never heard of this.. but me think you are into a new block...

Someone who have done this.. chime in.

Is there a repair procedure?

Jun 6, 2010 | 06:57 PM

UrbanXX

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I don't think you will have a problem with this once you intall the stud, it will seal the water jacket leak.
Use antiseize compound on the stud and run it in. You may get a little leak around it until it seals up. Then you should be OK. It should clog up any leak quick.

Jun 19, 2010 | 08:56 PM

KWest

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I fixed it today. I ordered up several drill bits, and 2 8x1.25 taps in preparation for today. I also bit the bullet and spent the $$ for the Ford studs. I ended up drilling 5 of the 8 studs, starting with a small bit and working my way to 17/64. Then I would tap the hole with the tapered tap, and finish it with a bottoming tap. On the hole that I drilled into the water jacket I used a pipe thread sealer and tightened it down good. All the rest got Never Seize. The truck sounds a lot quieter now, but since I fixed the large leak I can hear the smaller leak from the other side.

Jun 20, 2010 | 03:21 AM

DIXIEDOG1

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Quote:

Originally Posted by KWest

The truck sounds a lot quieter now, but since I fixed the large leak I can hear the smaller leak from the other side.

It's a vicious cycle, once you get that taken care of you'll start hearing squeeks and rattles...that's the best part about a loud muffler....your truck never sounds as bad.