1999 v10 header questions.
 

I have a 1999 f250 superduty with a 6.8 v10. I ordered the headman headers online and started putting them in yesterday. So far ive broke off 6 of the 15 bolts ive gotten out. Also the headers didnt have a spot for the EGR to thread into. So I need to delete the Egr. Ive found some delete plates but then there is also those other two lines that i have to do something with. Do they just need plugged. And whats the best option with the broken bolts? Ive got a mess please help.

Weld and drill are the options for bolts. Do you have extractors and stud removal tools?

I have a EGR delete from eBay, and Thorley Headers, haven't installed them yet though.

Check this tool out, available on Amazon Prime too.


Edit: Check out this thread too.

https://www.ford-trucks.com/forums/1473314-egr-delete.html

There are many threads in this forum with great pictures. Believe it or not 6 of 15 is not a crazy number for the V10. There are some tricks that may help. Instead of simply putting everything you have into turning the bolt out, try a little finese. If you can get it to turn out a tiny bit, turn it back in, continueing a back and forth movement until you win. If you can get oil between the head and the exhaust manifold put a little oil on each bolt and let it sit.

As I said there are many threads. To search, use the "Search Forums" box in the upper right corner of the screen, Next to the search box is the drop down that says "threads". Drop down and select "Advanced". Find the V10 forum and select that with your key word search. You should find threads with great pictures and advice. Unfortunately you will need to develop your machinist skills if you are not already good at removing the broken bolts. It is not going to be any fun!

Yeah i was doing them by hand and trying to go softly as i could. Ended up getting done with 6 broken off out of the 20. Going to start pulling the heads tomorrow. Ill likely weld a nut on each one to get them out.

How come you are pulling the head? I was able to weld a nut and remove the studs and for the ones that broke off below the head I welded a washer to the broken stud and then welded a nut to the washer I was able to do this without removing the heads

Mine arent broke off flush, they are broken deep up in the hole for the stud. Also the engine cradle wrapped up on each side so there isnt even any clearance for a right angle drill or anything.

if you're going to go through the trouble of pulling the heads make sure you get the cam lock tool and you should have your machine shop install the metal spark plug inserts.
this way you'll get rid of future stripped spark plug holes and won't rocket a plug and cop after your next plug change.
make sure you torque those plugs too. 25-28 lbs ft

I feel your pain. I was able to use my mig welder with flux core wire with the mig shield removed from the gun and build the end of the studs up enough to get nuts welded on. Didn't damage the aluminum at all. I would also figure out an egr fitting for the headers. Unless you have a tuner you will have a CEL