Exhaust Manifold Replacement Tips/Ideas - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 23 (permalink) Old 11-26-2011, 05:25 PM Thread Starter
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Exhaust Manifold Replacement Tips/Ideas

Hey Guys: Finally got done with the flexplate and up-pipe job what fun that was !!!!! At least the trans was out at that time. I got both manifolds today and the gaskets. Should I go with new bolts from ford and junk all the old ones if they come out in 1 piece ? Any other tips or tricks in making this job any easier with the least broken parts ? I know I should have done it with the trans out but ran out of time and needed the truck back running ? The drivers side manifold is leaking badly so im sure new stuff will help with EGT's ?

Thanks in Advance !

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post #2 of 23 (permalink) Old 11-26-2011, 07:16 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

Heat, time and patience and hope you don't break any. Otherwise pull engine.

I usually pull the engine and smack on either a 1/2" impact or 12mm depending upon which bolt it is. I soak everything in pb blaster, hammer on socket, heat up head, try to break it loose. If it doesn't work, repeat steps until it works or breaks bolt off.

Hopefully it breaks off in manifold if it breaks and not flush with the head. if it breaks off in manifold use a die grinder or sawsall to cut manifold off. Then try vice grips to spin the stud out. If that doesn't work weld a nut on the stud. All the while you need to be cycling heat, pb blaster and tapping it with a hammer.

If it breaks off flush with the head then you have to drill it out. I usually use left handed cobalt drill bits in the case you get lucky enough that it will spin itself out. I used to use easy outs but if they break off in the head they become almost impossible to drill the bolt out.

This is all why I normally just pull the engine and do this on the stand.

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post #3 of 23 (permalink) Old 11-26-2011, 07:27 PM Thread Starter
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Re: Exhaust Manifold Replacement Tips/Ideas

Well thats the answer I needed but was not looking foward too ! I have to agree 100% but what do you think the odds are of the wrost case scenario happening ? It has about 130,000 miles on it all original. I was hoping to do this without pulling the engine because that would kill my business.

97 F-350 CBLB 4WD
4 in Lift
Where's the cat/muff ??
Tymar Intake
Autometer Gauges
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post #4 of 23 (permalink) Old 11-26-2011, 09:28 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

2 tricks I will pass on you.
First is to just a sawzall and you can get the blade behind the manifold and cut most but not all bolts off as there is space back there to cut them. By cutting the bolts then the manifold will fall off and then just use vice grips to un thread them. I remove the inner fender well for the room.

Second trick that I do is being that you are replacing them, just use a air chisel on the manifold where bolt holes are and the air chisel will shatter the manifold in seconds and it will fall off and again use vice grips to just un thread them . They will unthread easy when not seized in the manifold

96 F250 XLT 4x4 210000 miles Dana 60, Baby Swamped,Tony Wildman tunes,AutoMeter Pyro Boost Trans ,DPP downpipe,Tymar intake BTS TRANS

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post #5 of 23 (permalink) Old 11-26-2011, 09:37 PM Thread Starter
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Re: Exhaust Manifold Replacement Tips/Ideas

Thats a good idea considering I am not trying to save the manifolds. So you are saying air chisel the manifolds first to break them apart and then sawsall or just one or the other ? Also anyone know the Ford part numbers for the exhaust manifold bolts of International numbers ?

97 F-350 CBLB 4WD
4 in Lift
Where's the cat/muff ??
Tymar Intake
Autometer Gauges
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post #6 of 23 (permalink) Old 11-26-2011, 09:40 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

one or the other. I sawzalled most of them and air chisseled the ones i could not cut but the air chissel would be the quickest being u are not saving them

96 F250 XLT 4x4 210000 miles Dana 60, Baby Swamped,Tony Wildman tunes,AutoMeter Pyro Boost Trans ,DPP downpipe,Tymar intake BTS TRANS

e99 f350 cc/lb drw php hydra plus Tony Wildman tune


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post #7 of 23 (permalink) Old 11-26-2011, 10:00 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

I am curios why you manifold are leaking.

The only time I have seen them leaking was broken manifold bolts

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post #8 of 23 (permalink) Old 11-26-2011, 10:05 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

Quote:
Originally Posted by diesel_brad View Post
I am curios why you manifold are leaking.

The only time I have seen them leaking was broken manifold bolts
remember the rusted plow truck i have with stuck 4x4 shifter??
the manifolds rusted out from salt on bottom where salt kept hitting them

96 F250 XLT 4x4 210000 miles Dana 60, Baby Swamped,Tony Wildman tunes,AutoMeter Pyro Boost Trans ,DPP downpipe,Tymar intake BTS TRANS

e99 f350 cc/lb drw php hydra plus Tony Wildman tune


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post #9 of 23 (permalink) Old 11-26-2011, 10:06 PM
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Re: Exhaust Manifold Replacement Tips/Ideas

Quote:
Originally Posted by excavator View Post
remember the rusted plow truck i have with stuck 4x4 shifter??
the manifolds rusted out from salt on bottom where salt kept hitting them
But he is in CA the land of NO SALT or rust

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post #10 of 23 (permalink) Old 11-26-2011, 10:25 PM Thread Starter
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Re: Exhaust Manifold Replacement Tips/Ideas

The drivers side manifold is leaking at the rear cylinder with a loud tick, and I was thinking the bolts maybe loose but I was nervous of trying to tighten them and having them break like I heard of. I just got done doing the up-pipes and flexplate so that is all thats left. The oil filter and bottom back part of the block is covered in soot !!

97 F-350 CBLB 4WD
4 in Lift
Where's the cat/muff ??
Tymar Intake
Autometer Gauges
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