F-150 exhaust manifold gasket replacement? (5.4)

[JosMN]

Just traded our Expedition on a 2001 Supercrew with around 127k on it (needed the box room, and my manhood back). The truck has the same type of ticking/or leaky exhaust manifold sound our expedition had when we got it with around the same amount of miles. It does go away some when the engine gets warm. My question is how hard is it to do yourself? Its more of something that annoys me more than anything, but could not pass up the deal on the truck. I did end up shelling out close to $600 to do both sides of the Expedition, which was an 02. 3 of the rear studs were broke off on the right side when I brought it in. That price was the cheapest that I could find here in town, and the guy did do great work on it. Just want to try and save some coin this time with the job. Anyone know of anybody in the Faribault area that would help me out, or a local guy that might do it on the side? The only thing I am scared of is breaking a stuff off inside the block. From what I can tell, there are no studs broke off right now. If I remember right with the Expedition, he did have to bring the manifold itself somewhere to be straightened because it has warped a bit. ANY help would be greatly appreciated.

[Scott K]

Well usually the leak is from broken exhaust studs. If there arent any busted now, chances are 50/50 that you will get all of them out without breaking any. I would get all new nuts and studs from the dealer, with new gaskets, and I would recommend slapping a straight edge onto the manifold and checking it for warpage as well. If no bolts break, its a 4 hour job, if they do break, 6+.

I would make sure to have a torch atleast before attempting the job.

[Farley]

I'm doing this to my 03 f150 right now and let me tell you it's not a fun job. I've managed to get 6 of the studs out so far, one was broken (by the leak) and the 2 I have left I cannot for the life of me get the socket to "grab" on the nut, of course they are the hardest ones to reach. Gonna try a rounded nut extruder tonite, hopefully that does the trick or I dont know what I'm going to do. I've been at it for well over 4 hours so far (over 2 days) and havent even started trying to get that broken stud out. I cant wait to get home and work on it some more!

[Scott K]

What I do with the broken ones is take a 3/8 nut, and a vise grip, weld the nut to the broken stud, then turn the nut while it is still hot, all most all of them come out very easy that way.

[K_Josh87]

I have not done this myself, but I have heard of this trick as well...

[JOHNBIGDOG]

What I do with the broken ones is take a 3/8 nut, and a vise grip, weld the nut to the broken stud, then turn the nut while it is still hot, all most all of them come out very easy that way.

This works, I can verify this.^^^^^^

Also tap one size smaller socket onto those stripped out nuts then use an impact to remove. Or those bolt extractors they sell at sears work great.

[Farley]

I ended up going with a larger socket and was able to get them off. The broken one is broke off down inside the hole. Going to have to drill it out and use a easy out. If that doesnt work, I guess drill it out and either helicoil it or tap it for a bigger stud, not looking forward to either. Praying I dont break off the drill or easy out inside the stud. I've had to deal with that in the shop here and its a pain even when the hole is centered up in a V-mill.