Broken exhaust studs? 3.5 EB

[frostylemonade]

105,000 miles. Previous owner used it to occasionally tow a small-medium camper (maybe 5,000lbs) but otherwise its just been a kid hauler.

Called around a little and was surprised at the wide range of answers from $1200 on the low end, which was a reputable independent shop quoting Napa manifolds, which I'm not going to use. I'm still undecided between updated Ford or BD Power. So realistically that shop is probably closer to $2000 by the time I use decent manifolds (more if I used BD Power because I would likely want both sides done). The high end was the Ford dealer, who acted like they've never heard of the problem, weren't aware of the updated Ford manifolds, and wanted to quote replacing the cylinder head as a worst case scenario. Give me a break.

I'm pretty torn. Thinking about ordering the BD Power and trying it myself. I'm fairly decent wrenching on things, but still intimidated by this project, both from a technical standpoint and considering the time commitment involved.

Or maybe we should just keep the 08 for now. Despite the higher miles, it's been a great rig and I believe it's still got some life left.

 

[gtr09]

I think the Ford expected hours is about 9 for this job, I'd plan for 12 at least. Doesn't seem complicated just about as miserable as it can get, esp if the stud is broken off inside the block. Here's a pretty good video. And another one. Don't forget you need a bunch of other parts, too, depending on what you take apart.

OEM Gaskets & Hardware Required:

• 1x HL7Z-9448-B 2017-2020 DS F150 3.5L Manifold Gasket (L / DS) Comes with BD power kit
• 1x HL7Z-9448-A 2011-2020 PS F150 3.5L Manifold Gasket (R / PS) Comes with BD power kit
• 2x HL3Z-9T516-A 2017+ F150 3.5L Turbocharger Oil Inlet Feed Seal
• 2x FT4Z-6N652-E 2017+ F150 3.5L Turbocharger Oil Drain Seal #1
• 2x HL3Z-00815-A 2017+ F150 3.5L Turbocharger Oil Drain Seal #2
• 6x FT4Z-6N652-D 2017+ F150 3.5L Water Inlet & Outlet Tube Seal #1
• 4x HL3Z-6N652-A 2017+ F150 3.5L Water Inlet & Outlet Tube Seal #2
• 6x W715673-S900 2017+ Turbocharger Mounting Bolt F150 3.5L & Raptor
• 4x W520514-S440 2017+ Downpipe Nut F150 3.5L (Recommended)

(The following only required if the Downpipe adaptor is separated / New turbochargers are installed )

• 2x BL3Z-9450-A 2017+ F150 3.5L Down Pipe Gasket
• 4x W716667-S900 2017+ Downpipe Stud F150 3.5L

2017 F150 & RAPTOR REQUIREMENTS

• 1x HL3Z-9448-C 2017 F150 3.5L Turbo Turbine Inlet Gasket (L / DS)
• 1x HL3Z-9450-A 2017 F150 3.5L Turbo Turbine Inlet Gasket (R / PS)

 

[JasonH]

I would go with the upgraded Ford part over BD Diesel. It's stainless, which is supposed to do a better job of handling the heat. The issue with the original wasn't just the studs...they keep the manifold flange affixed to the block. The manifold flange itself was deforming, and the studs are not intended to, nor strong enough, to prevent this from occurring. The updated Ford part is supposed to be more resistant to deformation. If you're not towing heavy, it may not be an issue either way. In comparison to the Ford parts, the Full Race parts are supposed to have better geometry, which reduces backflow and may help the manifolds stay cooler. They're around twice as much as the Ford parts, but this job is expensive, so makes sense to go with the best possible solution for the extra $$$.

On the Gen 1 for this model year, there is an oil feedline from the rear of the block. By all accounts, it's very difficult to access and to secure the oil properly. I feel like this is properly done as a cab off job. There are videos showing the installation process. I think this is one of those things you need to be really committed to tackling for the repair. It's really tight in there.