I have a 97 Expedition, and on the right side(passenger side), I have two studs that broke off holding the exhaust manifold. How hard is this to fix? Do I need to pull the motor to replace the studs? Can the exhaust manifold be welded/brazed to the head? It has 165000 miles on it, and runs/drives perfect. I hate the exhaust leak... Thanks for your help!

 

You don't have to remove the motor, but it is still a very difficult repair. Judging by your questions, you would be best to look for some professional help.

 

I had mine broken too. Took it to Ford Dealership and they replaced the manifold and three studs. One stud couldnt be removed and they put a commercial grade, extra heat resistant silicone over the badly rusted stud. total bill was about $600.

 

I had a friend that told me he had the exact same problem with his 5.4L. He was working on the transmission when he noticed he had studs broken on the exhaust manifold. He removed the remaining bolts, sprayed some liquid wrench on the stud and removed the broken piece with some pliers. Hopefully you have enough stud sticking out that you can grab it with some pliers. Anyway, he said the job was not extremely difficult and was amazed at how relatively easy the stud came out. Hope this helps some.