Ford Excursion :: 2000 V10 - Oil Leak After Exhaust Manifold Stud Repair
Jan 14, 2015
2000 excursion, 4X4, V10
A few days after the job was completed I noticed that the top stud on the driver's side closest to the firewall has signs of oil leaking from inside the hole. This is a hole that I had to drill and insert an 8mm Heli-coil. I was very careful on the depth of the hole I drilled. I tried removing the bolt and placing JB Weld high temperature epoxy into the hole and reinstalled the bolt. I waited over 24 hours for the epoxy to cure and then I checked for leaks. The leak re-appeared but has slowed down quite a bit. I have a USB endoscope that I will be using to inspect the inside of the hole to see if I can see where the leak is actually coming from. I am in no position to replace the head but I will do whatever it takes to get the truck back into service.
After 7 days in my garage, I finally removed/replaced all 20 manifold studs. I had to cut off all of the nuts to remove the manifolds. I was able to remove 17 out of 20 studs by using a 6 inch pipe wrench and a lot of coaxing. 3 of the studs were already snapped off inside the head. I drilled out two and was able to get them tapped for a Heli-coil. The third stud I broke a 1/8" cobalt drill bit inside and it took 4 days to get enough of the hole drilled out to get a Heli-coil inserted.
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The exhaust leak is not too horrible, but, enough that I need to address it soon. Only on the driver's side; (today).
I'm planning on having a lot of PB blaster on hand, torch, broken stud removers, screw/stud extractors (easy outs), ...a hammer. Maybe a few cold Budweisers
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I have a 97 Expedition with the 5.4 engine and 160k miles. Recently while having other work done I was told that I had an exhaust manifold leak due to broken rusted bolts.
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My truck just started running really loud when it's cold and the leak goes away when it warms up to operating temperature.I did a little bit of investigating and I have found where the leak is coming from at the end of the exhaust manifold where the donut gasket meets the catalytic converters. It appears that the bolts rotted that hold the system together at the gasket. What should I do to repair this? I don't really want to replace the whole manifold because I know I'll break a stud off in the engine because everything is pretty rusty down there. I even took some pictures of the problem....
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My wife's 97 f150 4x4 had an exhaust leak on the passenger side. 7 out of the 8 bolts holding the manifold on are snapped off. 4 of them are snapped off 1/8" below the top of the hole on the cylinder head . I am I unable to get a drill in to drill these out. The other 3 I've tried welding a nut on these but they won't budge and I wring the nuts off. If I have to pull the head(something I don't want to do)can I just pull that 1 head or do I have to tear the intake and everything off?
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This is a 2000 EX with 146k miles on it bone stock. I have not done any of the regular maintenance on it yet or even gotten to really check this problem out. I am not driving it at this time mainly due to this problem.
The noise is heard the best at the rear of the engine and underneath the truck as the video shows. It seems to slightly change in sound (maybe a tad bit quieter) once I put it in gear (drive and reverse), I have not really heard a change in it after the truck has warmed up either. It does not sound at all really metallic to me..
[URL] ....
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So I think I have possible manifold leak in my exhaust and its because when the engine is super cold, and I do have a straight pipe, but it sounds like a tractor... until it warms up after few minutes, it goes away.
My exhaust manifolds are rusted to crap and stuff is falling off, paint or whatever there was on them.
Now I've looked at bunch of videos on UT to get a better understanding since everyone says the nuts and studs are hard to remove or snap.
Now my question to anyone who's done this in their garage; I've seen bunch of videos where the stud snaps flush, then he takes a nut, puts it over the hole, holds it up with needle pliers and uses a MIG to start welding it... stud to nut... then puts a wrench and off it goes.
Now, I'm not a pro welder or anything so is it possible to by accident weld the stud, nut into the head and then never ever be able to undo or take either one out?? or is the head or whatever made from different material that won't get welded to the nut or the stud??
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I currently own a 2009 F-150 XLT, ext. cab, 4X4, 4.6l, 6R80 trans. Surprise, Surprise I have just developed an exhaust leak at the manifold collector. After some careful investigation, I separated the pipe from the manifold and the sealing surface is totally rotted away. I cleaned it up as best as I could and slathered some muffler cement inside the joint to seal the leak. It is about 80% better but will get worse again I'm sure.
I visited my local Ford dealer and talked to a friend I have working there and he said Ford has known about quality issues with manifolds for years and he was surprised that the manifolds lasted 70k miles.
I am hoping to use the truck as is through the winter and in the spring I am going to install these headers:JBA Headers - Reviews on JBA Cat4ward Exhaust Headers - Stainless, Ceramic & Chrome Finishes
This intake:K&N 63 Series AirCharger High Flow Cold Air Intake Kits Best Price & Reviews
This tuner:Bully Dog Triple Dog GT Tuner (49-State Legal) - Bully Dog GT Tuner Reviews on Gas Programs for Dodge, Chevy, Ford & Nissan Trucks
I already installed a Flowmaster American thunder catback exhaust system about a year ago...
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I have a 90 bronco with a efi 351w and im missing one nut for the manifold to exhaust pipe flange. I have looked all over the net and can't find the size I know its a 1/2in socket but I need the thread pitch and size, had the parts guy try to sell me the stud and nut kit seem really expensive for just a nut and to install the full kit I have to pull skid plates and the trany supports just to start to get room to do the job, seems like a lot of work to replace 1 nut...
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Truck has 107 thousand miles; had to take it in for an manifold exhaust leak. Mechanic said bolts are so rusted they break.
1) was there ever a ALERT from ford about these bolt's?
2) Thought i read ford had stainless bolts for this problem...
I've had F150's only since the mid 70's and this 04 has cost me more in repairs than ANY previous F150..
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I own a e1999 Ford F350 7.3 4x4 with a Garrett GTP38R turbo. I have been having issues with very little power and pulled an CEL of P0221. I know it's for the APS and have been trying to trouble shoot it as a new APS has not fixed the problem. However, while working on that I just noticed an oil leak appear. I tracked it down and can visibly see it leaking out the top of the passenger side exhaust manifold in two places. It is seeping out the top. Is oil supposed to even be running through here like that?
I recently replaced my up pipes with the newer style bellowed ones. While I had the turbo off I replaced all the o-rings top and bottom and did the EBPV delete on the pedestal. I have been having very little power and cannot the truck over 5-10 MPH and stays at low RPM's so I originally thought it was the leaky up pipes. Those were fixed along with fuel pressure checks which came back good. I then pulled the P0221 code finally. While I had the turbo off I inspected it and it did spin freely and had no side to side play in it.
What was unusual to me was there was a small pooling of oil in the turbo when I took it off. I know the CCV goes through here so some oil is normal. Also, when I was diagnosing the up pipe leak I could see a small amount of oil spraying out the blown donut gasket along with the exhaust gases. I don't think that is normal.
Is there an internal seal in the turbo that can go bad causing oil to spill into my exhaust and possibly leak at the exhaust manifold? Or do I have an internal oil leak from somewhere else?
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2004 SCrew, FX4, 5.4 ... I had the dreaded exhaust manifold leak on the passenger side. After reading the horror stories of this repair and living in the rust belt I decided against fixing it myself. I took it to a local repair shop to have done. Initially the mechanic could see that the front 2 studs were snapped off (before even trying to remove them).
After a full day of fighting the studs (engine loose & lifted up) everything is out but the front 2 studs. the top one has about 1/2" exposed, but it is frozen in place (penetrate on it overnight). The biggest problem is the bottom stud. it is broken off about 1/8" below the surface of the head. The guy doesnt have a small enough right angle drill to get between the frame & head to attempt to drill it out. I will gladly go buy a drill for him to do this, as it will likely save me money if it will work to drill out the stud.
Need to get the 2 studs out, particularly the bottom one, or what right angle drill may fit in there?
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I purchased my 2008 Explorer Ltd about 4 months ago with a 4.6L and 63k miles. I use it for towing a small travel trailer, so I don't put many miles on it. It's got about 66k on it now. According to OASIS, it has had all MFR maintenance performed up to the 60k mark.
In the past two months, it has developed a "sound" on startup. it goes away after about 75 seconds. To me it sounds like a typical exh manifold leak. That "3 cylinder, putt putt putt tractor" sound. There is no apparent affect on performance. It is definitely coming from the area of cyl #1. I have a recording here.
[URL]....
It is the "higher" of the sounds. The lower pulsing/whooshing is just regular engine noise. You can hear the regular engine noise as the camera pans to the back of the car.
What puzzles me is that the exh manifold sound goes away after 75 seconds or so. Holding the tailpipe shut for a bit builds up lots of pressure quickly. Do you think it IS, in fact, an exh manifold leak, and it seals up with thermal expansion as the engine worms up (75 seconds)? Is this a typical issue with the 4.6L
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I've got a 2006 F250 5.4l. Recently Ive had an issue when I am driving, usually when the engine is at 3k+ RPMs, where the engine will lose power and the cel with blink. Usually it only takes a few seconds for the blinking to stop and the engine continues as normal. Now, I know that at least one of my exhaust manifolds are leaking.
Could it be that the engine is not receiving enough back pressure and that is causing it to lose power? I had a similar issue last year, basically the same symptoms, and it turned out that I had two cylinders misfiring. I replaced the coil packs and that fixed it. This time there are no codes referring to a cylinder misfire. There is a code for EVAP leak (I think), but I was told it was nothing to worry about.
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is there a set of headers for my 2008 f250 5.4 rwd that will install somewhat easily without me throwing tools across the garage? I see a lot more options for the older trucks. I have a pretty annoying exhaust manifold leak and I figure I might as well throw some headers on if im gonna be in there. I really want to go for sound rather than power. I think I saw a set by flowmaster that looked decent.
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2003 F350 short bed 6.8L V10---On start up a slight tap sound, almost like a cranky lifter, but it is an exhaust manifold leak. At the bolts, I am not sure. This has been this way for 5 years, no better no worse. After I run about 2 to 3 minutes it seals itself. Not a hint of noise. Due to heat, something is expanding to seal it (aluminum).
At my annual PA. State Safety Inspection the Tech says 'that has to be corrected if it worsens', but It does not fail inspection. This puzzles me.
How is the call made for correction. A flip of the coin, a guess and is it serious enough to fail inspection. Is this normal with the 6.8L or V10s. I know the cost involved for a fix is big league, but can it be justified. TRUCK RUNS GREAT !---
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I have an 06 with a 5.4 with 70k on it and I have already had to do the exhaust manifolds twice, once covered by warrantee at 19k, then again around 40k and now at 74k I have a major leak from the left side manifold again
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So I was replacing a wheel stud and while taking the caliper out, I accidentally unscrewed the brake fluid bolt and it drained a little bit of fluid out. I had to decompress the caliper to put the brake pads in.
Everything was placed back the correct way, now the brake feels too spongy and I have to press the pedal all the way to stop the car. not feeling safe.
I'm not sure what needs to be done here.. did I somehow get air in the system? the brake fluid cap was on the whole time.
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Have to do a replacement and if so.. is removed the intake the only way to get at those stubs on the ex manifolds.
I thought it was the flex-pipe.. but after listening to the sound and getting an engine code for b1 s1 the leak has to be before the o2 senor for it to pop a code..
It sounds like a standard header leak from backing out bolts or a faulty gasket leak..
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I have V6 Tdi -08 and my car has developed a tiny leak on the right hand side exhaust manifold. The purchase price for a new manifold is not to expensive but I now wonder difficult it is to replace considering how tight it is in the engine bay. If the engine has to come out in order to have it replaced or repaired.
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Should I attempt to replace the passenger side manifold with what I can get from Napa. I would rather pay 100 bucks for everything and do it myself. But, Im concerned about replacing the studs. From what I have read the studs seam to be the problems for most leaks on these vehicles. I have torque equip. and other tools to do the job. Just want others opinions about this project. How hard really is it? 1999 5.4L F250 SDuty....
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