Exhaust manifold poll
#1
Exhaust manifold poll
How many of us have had to replace the manifolds on our 5.4's? It starts out as the studs rotting off the manifold then you get warpage of the manifold.We have six and we're batting 1000 right now. We have been thru three sets with one truck and went to stainless headers and ARP manifold bolts. So far all is good! The newer 5.4's seem to be better with the redesign, but you have to wonder how many 5.4's are out there and the manifolds are rotting off and there has been no TSB or recall.
Jim
Jim
#2
1998, F150, 5.4, auto, 3.55 LS, Reg. Cab. 8'bed. 87k
Rusting off is a understatement.
Mine are about to give me problems. I can't belive they are not leaking yet. They are so rusted that the manifold bolts don't even look like bolts at all. Seems like a common problem with the early 5.4L. The local auto tech said he has seen several that had to be replaced.
When it comes time I'll put on a S.S. set. Rainoneinc has the right idea. To be honest I've never had a car or truck with so much rust buildup on the manifolds.
It will be a major problem trying to remove the old ones due the the corrosion and tight working conditions.
Don't hold your breath on the TSB.
Rusting off is a understatement.
Mine are about to give me problems. I can't belive they are not leaking yet. They are so rusted that the manifold bolts don't even look like bolts at all. Seems like a common problem with the early 5.4L. The local auto tech said he has seen several that had to be replaced.
When it comes time I'll put on a S.S. set. Rainoneinc has the right idea. To be honest I've never had a car or truck with so much rust buildup on the manifolds.
It will be a major problem trying to remove the old ones due the the corrosion and tight working conditions.
Don't hold your breath on the TSB.
#5
99 F-150 with the 5.4
Started getting the dreaded exhaust manifold leak around 75K miles. The 2 rearmost studs on the passenger side completely rusted/broke off flush with the manifold.
Drove around like that for a couple years. Around 95K miles I started getting a SES light and lean codes due to air getting sucked in around the leaking manifold and hitting the downstream O2 sensor. Reset the DTC codes and they kept coming back.
Took it to the shop, attempts to extract the broken studs failed...had to drill them out. Installed a set of stainless JBA headers and the SES light/lean codes have not come back since.
It's quite a common problem among F-150's, F-250's, Expeditions, etc. we all know this too well. I understand Ford has a new stainless steel stud kit that they sell to correct this problem. I love how Ford comes up with these genius solutions after the fact (spark plugs anyone?)
Started getting the dreaded exhaust manifold leak around 75K miles. The 2 rearmost studs on the passenger side completely rusted/broke off flush with the manifold.
Drove around like that for a couple years. Around 95K miles I started getting a SES light and lean codes due to air getting sucked in around the leaking manifold and hitting the downstream O2 sensor. Reset the DTC codes and they kept coming back.
Took it to the shop, attempts to extract the broken studs failed...had to drill them out. Installed a set of stainless JBA headers and the SES light/lean codes have not come back since.
It's quite a common problem among F-150's, F-250's, Expeditions, etc. we all know this too well. I understand Ford has a new stainless steel stud kit that they sell to correct this problem. I love how Ford comes up with these genius solutions after the fact (spark plugs anyone?)
#6
It's quite a common problem among F-150's, F-250's, Expeditions, etc. we all know this too well. I understand Ford has a new stainless steel stud kit that they sell to correct this problem. I love how Ford comes up with these genius solutions after the fact (spark plugs anyone?)
#7
My consternation comes from the fact that we have seven 250SD. ALL so far have had issues until the 2007 with the redesign. My old truck went through three sets before we put Gibson stainless headers (PN G276P206S) on and no problems yet. On more than one truck we had to pull the engine to get to all the studs. I don't know about you warmer climate guys, but we plow snow and salt and I'm sure that has more then aggravated the issue. My point of the post is that the 5.4 is in what...Crown Vics, Expeditions, trucks, what else? If it is just that three vehicles then you have to go with the thought that the F-series truck was the most popular truck for quite some time, then you have police cars/taxis/etc and all the soccer mom cars. That's a-lot of rusted studs and warped manifolds. Is this programmed failure? Makes me wonder. I'm a Ford guy to the core (just look in my garage), but this is really a POS design I'm sure they know about. I know Ford was quick to recall cars after the whole Explorer tire debacle and I know it cost them a mint as well. Wonder if Ford knew but couldn't shoulder the expense of a recall?
OK, I'm done whining now....
OK, I'm done whining now....
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