3.5 Exhaust Manifold replacement recommendations

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Kathy

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Can anyone recommend what manifold they used to replace the warped exhaust manifold(s) on their 3.5 Ecoboost??
Thanks,
Kathy
 

tcbrad98

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I second that question, I don’t really want to just replace with the same ones.
 

JasonH

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I haven't had this work done yet, but I have heard mine chirping and looked into replacement. The most popular options are BD Diesel and CR Performance. Supposedly the CRP can warp again. BD claims their design uses all stud locations on the engine block. Interestingly, Ford appears to have released new parts. You can see a discussion of the differences in the li k below:

 

SteveMax15

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Dealer just informed me my manifold warped and broke an exhaust stud. My car 'chirps' on cold start but the tech confirmed the problem was the ex manifold and not the turbo. I got an estimate for $2500 that includes a new manifold, replacement stud(s) and the Ford recommended "extra stud" that I cannot add more info on what the extra stud is. It also includes gaskets and some sort of oil and coolant connections (what??).
 

99WhiteC5Coupe

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Dealer just informed me my manifold warped and broke an exhaust stud. My car 'chirps' on cold start but the tech confirmed the problem was the ex manifold and not the turbo. I got an estimate for $2500 that includes a new manifold, replacement stud(s) and the Ford recommended "extra stud" that I cannot add more info on what the extra stud is. It also includes gaskets and some sort of oil and coolant connections (what??).


What year?
 

JasonH

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My understanding from what I've read is that there are three stud locations that the OEM manifold did not employ as clamping points in its original design. I think one of those is now used for the new revised Ford manifold, and the BD Diesel uses all of them. The coolant and oil connections are for the turbo and I believe are recommend replacement items. There are many videos online detailing both manifold and turbo replacement. It's supposed to be straightforward provided the studs don't break in the block. I suggest calling around for parts and labor quotes. I've seen four to five hours labor quoted for a competent mechanic. No clue what the total for parts runs. I have at least eight Ford dealerships in my metro area and prices wary widely between them.


Dealer just informed me my manifold warped and broke an exhaust stud. My car 'chirps' on cold start but the tech confirmed the problem was the ex manifold and not the turbo. I got an estimate for $2500 that includes a new manifold, replacement stud(s) and the Ford recommended "extra stud" that I cannot add more info on what the extra stud is. It also includes gaskets and some sort of oil and coolant connections (what??).
 

JasonH

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Here's a video I watched previously that shows what's involved in replacing the manifold.


And one that shows the new manifold with the extra stud location.


And here's a new OEM replacement part I just found out about. The product page provides some insight into the cause for the OEM part failure.

 
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Silver-Bullet-Bus

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Can anyone recommend what manifold they used to replace the warped exhaust manifold(s) on their 3.5 Ecoboost??
Thanks,
Kathy
Best bet would be the new full race, formline manifold.

I also think bd diesel makes some, & also CR Performance, but the later two mentioned might not work wit Garrett snails, if u were even thinking of upgrade your turbos.
 
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Kathy

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Thanks, we went with the BD Diesel ones with the turbo install kits as well. My husband installed them a few weeks ago along with replacing one of the turbos that had an internal oil leak with an OEM one from Ford.
So far so good. We towed our travel trailer last week and it's got plenty of power and no problems.
 
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