3.5 Exhaust Manifold replacement recommendations

[Kathy]

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

 

[tcbrad98]

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

 

[JasonH]

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:

diff swap, 3:73 to a 4:56 - Ford F150 Forum - Community of Ford Truck Fans

Performance, Tuning, and (LEGAL) Racing - diff swap, 3:73 to a 4:56 - Hello, I have a 2008 F150 Fx4 with a 5.4L in it. I'm running 35's on it with a 6 lift. it currently has a 3:73 Gear ratio. with a 9.75In rear end. I'm wondering if anyone knows whether this rear end will accept a 4:56 gear swap

www.f150forum.com

 

[SteveMax15]

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]

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]

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]

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

F-150 Ecoboost 3.5 Exhaust Mainfold/Stud Replacement (Tips and Tricks)

If you have found this video helpful, and you wish to donate to me, follow this link!! its easy!!https://paypal.me/aaronhinesauto?locale.x=en_USFollow this c...

www.youtube.com

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

Ford 3.5L EcoBoost Broken Exhaust Manifold Stud | Everything You Need to Know

[email protected] Thanks for watching! Subscribe & Ring Bell: https://www.youtube.com/channel/UCKKl-ZyWum3HvjCqliw1OmwBrunt Website: www.bruntworkwe...

www.youtube.com

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.

Full-Race 2011-2016 Ford F-150 3.5L EcoBoost Formline® Turbo Manifolds

Replace the restrictive, failure-prone OEM exhaust manifolds on your 2011-2016 Ford F-150 EcoBoost with Formline® Turbo Manifolds. Engineered from premium 347 stainless steel, these 100% bolt-on manifolds deliver improved exhaust flow, increased horsepower, and unmatched durability.

www.full-race.com

 

[Silver-Bullet-Bus]

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.

 

[Kathy]

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.

 

[tcbrad98]

I had both replaced under warranty with the new redesigned ones from Ford.

 

[JasonH]

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.

Kudos to your husband! I've watched several videos on the repair, and I've decided that I know my limits. I just don't have the space or time to have the truck in pieces in my driveway. I suggest locking out the 6th gear when towing. I think the manifold warpage is caused by heat buildup from the turbos. The BD Diesel manifolds are still cast...the stud may not stop them from deforming if they get too hot. You can reduce heat by using a lower gear, as the turbos will generate less boost in lower gears. Also use 91+ when towing.