Exhaust manifold repair.

Jeff55v · Jun 26, 2017

I guess the OE exhaust manifolds on my 5.4L are steel, rather than cast iron. When investigating an exhaust leak, I found one of my manifolds was rusted through! I've never seen this on an OE manifold before. As you can see, the manifold bolts are too rusty to make manifold replacement feasible.
I patched the leak with a high temperature epoxy putty. I don't know how long it will last, but so far, so good.
Sorry, pictures are in reverse order.

ExplorerTom · Jun 26, 2017

Wow!

I haven't looked at mine but mine does "tap" when cold and goes away once warmed up.

Big Brian · Jun 26, 2017

yeah I doubt it will last long. Problem is the header will keep rusting under the patch and deteriorating and the epoxy will loose its grip

worth a try though

Dewayne · Jun 26, 2017

That's what my 99 looked like when I bought it . Actually not that bad to change if you have a welder to remove broken studs.

juan214 · Jun 26, 2017

Found the same issue on 2001 F-150 one

docraymund · Jun 27, 2017

Replace it as soon as you can. Maybe you could get one at your local pull-a-part. The rusted bolts will be a problem if you delay it.

harliemae · Jun 27, 2017

The best place to order the manifold is from Rock Auto. And if you Google the hardware for the manifold it will take you to a link on eBay where there's a company that now makes stainless steel studs and nuts so you don't have to worry about them breaking again. If you go to use RockAuto if you Google find me a discount for RockAuto there's plenty of people on there that have the code to get you an additional 5% off. It's legit sites it's nothing that you have to join. And if you're not familiar of RockAuto if you get the code you put the numbers in where it says where did you hear about us from. Even with shipping it wasn't that bad ordering them from them. If I remember correctly it was like 50 or $60 savings over places like AutoZone and advance. I could be wrong about exactly how much it's been a few years but I know it was cheap enough for me to order from there.

rjdelp7 · Jun 27, 2017

This is a common problem on 4.6l and 5.4l. Its is one the reasons, my next vehicle will not be a Ford. I am pretty sure the bolts break, between the head and manifold. The nuts in photo may already be broke. Once the head is off they can be extracted, with vise grips or a special extraction tool. The shop that did mine, was familiar with this job. The mechanic said, enough of the stud was left to remove it. If it breaks off in head it is much harder. The new studs are "better" quality and are much stronger. One of my manifolds cracked, after it started leaking. I also, have never seen a manifold do this. It cost around $500-$600, per side, depending on number of broken studs.

juan214 · Jun 27, 2017

I have both the Stainless Steel kits on my truck. Just torque them to spec then double check them. Don't forget the thread locker on the stud and nuts. The Y-pipe bolts backed off a little over two years nothing an impact gun couldn't fix. Bolts, nuts and studs all still look new.

1955moose · Jun 27, 2017

They make a great penetrant called kroll oil. My spelling might be off, but it really creeps into rusty bolts/ studs. That along with patience can get the nuts loose. Replacement manifolds that are not cast iron would be a good choice. Maybe a nice aftermarket header.

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Exhaust manifold repair.

Jeff55v

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ExplorerTom

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Big Brian

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Dewayne

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juan214

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docraymund

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harliemae

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rjdelp7

2000 XLT

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