2006 - F150 Exhaust Leak
 

Just wondering if anybody can help ? I own a 2006 - F150 FX4. it has a 5.4ltr V8 and has just started to leak exhaust. I'm assuming it's coming from the exhaust manifolds. When I start the truck the sounds dissipates after about 5 seconds. I've just recently been advised that Ford uses a real short manifold bolt and the manifolds warp and leak because of this. Does anybody have any suggestions as to fixing the bolts as I realize lots of manifold bolts crack off in the head when removing them and will I have to machine the manifolds to get a proper fit upon reinstalling them.

Like I said any help would be appreciated
Farmdog

It's nice to know you're very aware of the potential pitfalls of working on this. Yes, the manifolds were pretty prone to warping and cracking. But the real problem is the studs. If you're VERY lucky, the studs will come off with the nuts (these are very commonly availible, and don't cost that much for the set to replace). I get stuck with all the 3.0L escapes that I have to take the rear manifold off to do anything to the trans, and this is the same thing. I have a center drilling setup (made by Blue Point, I think) that gives you a drill bit and collar to center the drill with, and then you can insert a little rod with a nut that you use to remove the broken stud. I would also suggest that at your earliest leisure, start to soak the studs w/penterating oil, and let it work. That sometimes helps. I see many of these where studs are broken and never fixed, and sometimes, it won't leak. The only other thing i would say is that once the stud breaks, it's usually (NOT ALWAYS) that hard to remove the broken piece. It can be done, but takes a lot of patience. Good Luck!