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

 

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.

 

if you need some cheap i have 2 sets of manifolds for the 2v 5.4 just laying in the snow, the one drivers side only has about 8k on it.

 

'02 F150 4x4 5.4L w/ 112,000

Passenger side leaks terribly, going with ceramic coated Pacesetter shorties in the spring

 

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?)

 

GM's have the same problem with the studs breaking off.

 

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....

 

it has to deal with putting aluminum next to steel. mine went to the ****ter after 70 or 80k. i didnt replace with stock and have had no problems.

i dont think its fords way of trying to make an extra buck. more than half of the people replace their manifolds with headers anyway.

 

Back when I had my 97 I replaced the manifolds with a set of gibsons shorty headers. Didn't replace them because of rust though, was just looking for a little more performance. Manifolds on my 05 don't look that bad yet.

 

Hey Jim,
my mufflers are starting to rust,,ya think they'll have a TSB or a recall?

Phil

 

I just bought a 99' 5.4 with 85k. Truck runs nice but it does have that passenger side exhaust manifold leak.

 

My 03 5.4 only has 37,000 on it, but I have a feeling that it's not about mileage, but time. Do you guys think I should pull them while I still can and replace them with headers or wait and see?

Bob

 

rainoneinc you might want to check out what we have to offer now.
We could work out a deal if you want to outfit all your trucks with our headers

 

Oh cool,,,free stickers!!!

Phil

 

i had a 97 f150 and i currently have a 01 250. both had passenger side rearmost studs busted off but they still sealed up ok after they warmed up. always seems to be the passenger side manifolds that rust away faster.