Exhaust manifold bolts failure

[Ericcccccc]

Hi All,

I have a 2017 Ford Expedition (125K) - I noticed that there was excessive exhaust noise on start up. I had my mechanic look at it and he said the the nuts had broken off the studs (both right and left). He got me this pic.

So what do you think my options are here?

1. Replace the just the one stud?
2. Replace all of the studs?
3. Replace the stud and manifold?
4. Temp fix with a bracket?

I really want to keep this truck forever. Man..... But the labor bill on this is going to kill me. PIC are below

Any fresh ideas would be appreciated.

Ericccccccc

 

[JasonH]

Most just replace the manifold(s). It warps because the cast iron can't handle the heat the the turbos generate. You can use the upgraded Ford stainless parts or aftermarket parts, like Full Race. The Full Race parts are like twice as much, but they also flow better, which mean less heat. If you have the manifolds replaced get all the turbo lines replaced with the upgraded Full Race AN lines as well.

I had to do this work around a year ago and yes, it's very pricey. I was basically in the same boat though...the vehicle is paid for and the repair was cheaper than a new one. I'm into it for like $9,000 between the manifold and timing chain repairs. But if I can keep it running for another 4 years, I'm cool with that. The 4th gens have cam phaser and 10-spd issues, so the devil you know...

 

[Ericcccccc]

Thank you for the response. I found this Kit from BD Power.
https://us.bdpower.com/products/exhaust-manifolds-ford-f-150-3-5l-ecoboost-2011-2016

It includes all the necessary parts and has an additional kit for the Turbo gasket and bolt kit.

https://us.bdpower.com/products/exhaust-manifold-install-kit-ford-f-150-3-5l-ecoboost-2011-2016

-------------

I am going to present these to my Mechanic and ask his opinion - and see if he thinks I am over thinking this... or what.

 

[Trainmaster]

This is a common problem with Ford engines. The studs are thin and, as was said, the manifolds warp. I've replaced them in a 2001 and had a broken one in my 2008.

I'm not sure if the six cylinders' are easier to access than the eights'. The eights are troublesome and not a fun job.

I would replace them all on that side. You really have to remove the manifold to get the broken one out, so they all should be replaced. There are special tools available to help drilling out the broken studs.

There are also "brackets" made to somehow "jury-rig" a fix for twenty bucks and fifteen minutes. I have no idea if they're worth the time. You may want to check this out:

Exhaust Manifold Leak Cheap Fix?

Anyone have experience using the Kral brackets on a 5.4 3v Triton? https://kralautoparts.com/wp-content/uploads/2023/12/KAP-Brochure.pdf This kind of bracket attaches to the head and uses a bolt to push the manifold back down against the gasket/head. Seems like a good short term solution if...

www.expeditionforum.com

 

[justbecause]

i got off the phone with full race. they were very patient with me going over my noob level questions
I asked them what the deal with their manifolds are. He said yea the BDs are a lot cheaper and better than stock but still cast iron and they are going to heat warp and break and I'll be replacing them regardless of how thick they make the cast iron thats just not the part for the job. He said theirs are a one and done. He said you dont want to do this job twice. I said I dont want to do it at all, he said wait until I'm doing it and see how I feel. I said I had yet to find a single person who said this was an enjoyable job, he agreed its very tedious and difficult.
I have called around to a half dozen shops everyone is in the $5,000 ballpark for turbos and exhaust manifolds. Posts from 2-3 years ago I saw lots of people saying that got it done for 2500. Those days seem to be long. I cant get turbos for much less than a grand, then 700 bucks for the AN fittings 10 hours of labor... Or I order the borgwarner turbos from full race the kit that comes with AN fittings and its only a little more than parts store/reman turbos
Or I spend a little more and get the screamers and add the AN fittings.... I'm trying to decide how deep to dig this hole or if I just keep an eye on my oil/coolant levels and let the turbos weep another year or two and see what happens.

 

[Fastcar]

Thank you for the response. I found this Kit from BD Power.
https://us.bdpower.com/products/exhaust-manifolds-ford-f-150-3-5l-ecoboost-2011-2016

It includes all the necessary parts and has an additional kit for the Turbo gasket and bolt kit.

https://us.bdpower.com/products/exhaust-manifold-install-kit-ford-f-150-3-5l-ecoboost-2011-2016

-------------

I am going to present these to my Mechanic and ask his opinion - and see if he thinks I am over thinking this... or what.

I guess it depends on how long you plan on keeping it. The parts price seems decent for what your getting. It the xtras and labor that will hurt.

 

[BigOleFordFan]

I guess it depends on how long you plan on keeping it. The parts price seems decent for what your getting. It the xtras and labor that will hurt.

^^THIS^^

A few years ago, I had the right side manifold replaced at a stealership....the parts weren't that much, but the labor killed me, since they had to cut/grind/torch off the OEM bolts, remove the manifold itself, then drill out & tap some new holes for the new, stainless steel studs, then replace the gasket and install the new manifold....

All said & done it was ~$1350 IIRC.....