broken exhaust manifold studs

broken exhaust manifold studs

PostBy: Rob R. On: Mon Aug 26, 2013 6:21 am

My '99 F350 finally let me down...the V10 sheared off three studs at the rear of the driver's side exhaust manifold. Manifold warped, gasket blew out, LOTS of noise, oxygen sensor very confused... :mad: :cry:

Passenger side isn't leaking yet, but it has already lost one stud. Just looking at this job is enough to make me cry, everything will need to be heated, studs drilled out, ugh. I managed to find someone that has done quite a few of these jobs and is confident they can handle it, but the parts are still pretty pricey. I dropped the truck off yesterday, with any luck it will be back in action in a few days.

I did not take any "before" pictures, but I will post some when things are buttoned back up. I blame the failure on a crappy design and 14 years of Northeast winters. Being a plow truck, those manifolds have sure been blasted with a lot of slush and water loaded with salt. The manifolds are longer than average (5 cylinders), and do not expand/contract at the same rate as the aluminum head. There is no expansion joint in the manifold like a lot of commercial engines use, so the expansion puts a lot of stress on the very small studs. I bought Dorman (aftermarket) manifolds for the repair, and it was nice to see that they have slotted the holes at each end of the manifold. The center holes fit tightly on the studs, but as you move left or right the holes are larger and/or slotted...allowing for some movement.

One thing worth mentioning, the mechanic said a lot of people run the truck way too long with a leaking manifold. He has seen some where the aluminum mounting surface on the head gets etched.
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Other Heating: Dad's 1953 EFM Highboy

Re: broken exhaust manifold studs

PostBy: I'm On Fire On: Mon Aug 26, 2013 6:35 am

That happened on my buddies 2006 F-150 he took it in to get repaired and they could only get one side done. He ended up trading the truck in after that. For the one side they did repair it wasn't cheap. Good luck, hopefully they get it fixed right for you.
I'm On Fire
 
Hand Fed Coal Stove: DS Machines DS-1600 Hot Air Circulator

Re: broken exhaust manifold studs

PostBy: coalnewbie On: Mon Aug 26, 2013 9:01 am

Those v10s were trouble. I had an exhaust manifold leak on the passenger side at the front. Apparently, the manifolds were not perfect from the factory and they all tend to leak there. So far I have 30,000 miles of blow by and still going strong. The only solution is from Gale (Banks not mining) as their after market exhausts meant they had to cast a new manifold. LOL
coalnewbie
 
Hot Air Coal Stoker Stove: LL AnthraKing 180K, Pocono110K,KStokr 90K, DVC
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Re: broken exhaust manifold studs

PostBy: Rob R. On: Mon Aug 26, 2013 9:51 am

The Banks headers are a great product. I know someone that put a set on a V10 powered motorhome.

The passenger side on mine has not leaked yet, but I know it is only a matter of time before it breaks more studs.
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Other Heating: Dad's 1953 EFM Highboy

Re: broken exhaust manifold studs

PostBy: SMITTY On: Mon Aug 26, 2013 11:09 am

While doing the front ball joint on a neighbor's Expedition, I was looking at the manifolds after I yanked the plastic fender out. Looks like it would be easier to replace the engine than the manifolds!! :shock: :shock:

What a shitty design! :roll: Up here they usually blow out around age 9 or 10.

Your not the only one though - every single Ford of that vintage that passes by here has the notorious TICK TICK TICK TICK TICK as they pass. Every one I passed on the highway the other day sounded the same! Engineered failure. Great - thanks Ford! :mad:

At least your not trying to Helicoil the #9 & 10 spark plug holes. Don't know which job is worse ... :(
SMITTY
 
Stoker Coal Boiler: Patriot Coal - custom built by Jim Dorsey
Hand Fed Coal Stove: Harman Mark III (not currently in use)
Coal Size/Type: Rice / Blaschak anthracite
Other Heating: Oil fired Burnham boiler

Re: broken exhaust manifold studs

PostBy: coalnewbie On: Mon Aug 26, 2013 11:12 am

TICK TICK TICK TICK TICK as they pass


Yep, that's the blow by an average piece of Ford engineering.
coalnewbie
 
Hot Air Coal Stoker Stove: LL AnthraKing 180K, Pocono110K,KStokr 90K, DVC
Hand Fed Coal Stove: Hitzer 50-93,
Baseburners & Antiques: Invader 2 Wings Best, Glenwood #8 + Herald 116x
Coal Size/Type: Rice, Chestnut
Other Heating: Heating Oil CH, Toyotomi OM 22

Re: broken exhaust manifold studs

PostBy: SMITTY On: Mon Aug 26, 2013 11:14 am

To top it all off, they build NOTHING with the mechanic in mind. While doing that lower ball joint, it took me an extra 4 hours taking things apart that did nothing to help the knuckle taper clear the ball joint stud. What a dumb design! Never seen anything like it! I ended up yanking the whole lower control arm, after I found the upper ball joint stud would just spin .... and the upper control arm bolts were blocked by the strut ... :bang:
SMITTY
 
Stoker Coal Boiler: Patriot Coal - custom built by Jim Dorsey
Hand Fed Coal Stove: Harman Mark III (not currently in use)
Coal Size/Type: Rice / Blaschak anthracite
Other Heating: Oil fired Burnham boiler

Re: broken exhaust manifold studs

PostBy: I'm On Fire On: Mon Aug 26, 2013 11:37 am

SMITTY wrote:To top it all off, they build NOTHING with the mechanic in mind. While doing that lower ball joint, it took me an extra 4 hours taking things apart that did nothing to help the knuckle taper clear the ball joint stud. What a dumb design! Never seen anything like it! I ended up yanking the whole lower control arm, after I found the upper ball joint stud would just spin .... and the upper control arm bolts were blocked by the strut ... :bang:


Smitty, you haven't yet learned that those who engineer and design vehicles don't actually work on them? I don't care what make or model it is they all suck to work on. Half the *censored* you sit there scratching your head going, 'WTF was this engineer thinking?'
I'm On Fire
 
Hand Fed Coal Stove: DS Machines DS-1600 Hot Air Circulator

Re: broken exhaust manifold studs

PostBy: whistlenut On: Mon Aug 26, 2013 12:07 pm

I wish it were only the Fords that break exhaust studs......MANY Chevy's also. Funny I don't hear about it much on Dodges.......hmmmmm. Aluminum and cast are not good neighbors.....
Last edited by whistlenut on Mon Aug 26, 2013 8:48 pm, edited 1 time in total.
whistlenut
 
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Re: broken exhaust manifold studs

PostBy: franco b On: Mon Aug 26, 2013 1:43 pm

Seems like a job for nortcan and rope gaskets and furnace cement.
franco b
 
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Re: broken exhaust manifold studs

PostBy: DePippo79 On: Mon Aug 26, 2013 3:12 pm

Never had any problems with Dorman manifolds. You should be good for a while after repair.
DePippo79
 
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Re: broken exhaust manifold studs

PostBy: Rob R. On: Fri Aug 30, 2013 8:14 pm

Just got back from checking on the truck. Manifolds are done. Sounds like a brand new truck, very quiet. The man that did the job said it took about 7 hours. One manifold was aftermarket, so it had been replaced once already. Whoever owned it at that time must have run it a long time with a leak, because the cylinder head was etched on three different cylinders...one of which was not leaking when I started this thread. He torched everything off and put it back together with a smear of coppper RTV on the etched cylinders. Just to make the job more interesting, the dipstick tube was rotted off flush with the block. Somehow he got that out out and installed the new one while the manifold was off. The only downside to the job is that I have to dish out a little more $$...when the inner fender was off it became very obvious that the power steering lines need to be replaced. One is already leaking, and of course they run between the frame and plow frame up to the cooler in front. Not a 5 minute job to replace them. The lines will get ordered tomorrow and he will finish the job next week.
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Other Heating: Dad's 1953 EFM Highboy

Re: broken exhaust manifold studs

PostBy: freetown fred On: Fri Aug 30, 2013 8:52 pm

We can only hope it doesn't snow real bad over the week-end :bang: toothy
freetown fred
 
Hand Fed Coal Stove: HITZER 50-93
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Re: broken exhaust manifold studs

PostBy: jpete On: Fri Aug 30, 2013 8:58 pm

I'm On Fire wrote:
SMITTY wrote:To top it all off, they build NOTHING with the mechanic in mind. While doing that lower ball joint, it took me an extra 4 hours taking things apart that did nothing to help the knuckle taper clear the ball joint stud. What a dumb design! Never seen anything like it! I ended up yanking the whole lower control arm, after I found the upper ball joint stud would just spin .... and the upper control arm bolts were blocked by the strut ... :bang:


Smitty, you haven't yet learned that those who engineer and design vehicles don't actually work on them? I don't care what make or model it is they all suck to work on. Half the *censored* you sit there scratching your head going, 'WTF was this engineer thinking?'


Cars are designed to be ASSEMBLED quickly. What happens after isn't a concern.
jpete
 
Hand Fed Coal Stove: Harman Mk II
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Re: broken exhaust manifold studs

PostBy: Rob R. On: Wed Sep 04, 2013 6:05 am

freetown fred wrote:We can only hope it doesn't snow real bad over the week-end :bang: toothy


45 this morning, starting to get nervous. :)

I tried to get the power steering lines through Ford. Almost $300 and they were backordered. $50 for the set from Advance Auto, and they were on the shelf. :what:

I ordered a new steering stabilizer also, hopefully that stops the truck from "dancing" when I hit railroad tracks. At least the balljoints and such are nice a tight.
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Other Heating: Dad's 1953 EFM Highboy