What did i get myself into...

[Jeremy airjer W]

This 2007 Ford F-150 came into the shop yesterday morning for a ticking noise from the engine. Turns out the passenger side exhaust manifold is severely rotted and has one broken stud. I have not tackled one on a 3 valve 5.4 so I do dome checking and it seams pretty straight forward. Unbolt the motor mounts, remove the starter, move the A/C compressor out of the way, jack up the motor, remove the old one, and install the new one............ Unless a stud is broken!

 

With the engine removed the broken stud could be removed and the new exhaust manifold installed. There is no room in between the manifold and the strut tower for a drill (straight or angle). The only option is to pull the engine.

 

Broken Stud

 

Step one remove the intake plenum

 

Engine on its way out

 

Broken stud removed

 

New studs installed

 

New Manifold installed

[delcecchi]

OUCH.  Looks expensive.  

[Macgyver55]

 I suppose there was not even a little bit sticking out from the surface of the head! 

 Removed plenty of them by putting a nut over the stud and tack welding it on when they had something sticking out of the head. That one looks nasty! I'm definitely not jealous!

[leech~~]

What did i get myself into...

Auto Repair remember now!

 

I know we all like to whine about our repair bills.

But we love ya Man!

[Jeremy airjer W]

1 hour ago, Macgyver55 said:

 I suppose there was not even a little bit sticking out from the surface of the head! 

 Removed plenty of them by putting a nut over the stud and tack welding it on when they had something sticking out of the head. That one looks nasty! I'm definitely not jealous!

 

It was about 1/16" inside the hole. The other one that broke left just enough to grab with a stud installer. A little heat and came right out.