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5.4 Exhaust manifold leak

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Old 09-15-2010, 01:24 PM   #1
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Default 5.4 Exhaust manifold leak

so before anyone says "search noob!" i did and i couldnt find any helpful info about replacing an exhaust manifold gasket on a 5.4 themself. my right side manifold leaks at idle untill the truck warms up and it also does it under light throttle while pulling a hill in OD or while towing and its driving me nuts! i want to tackle this job myself but looking at where the manifold is located being so close to the fame rail/ shock tower it looks like it will be a giant pain in the ***. anyone here done this with any success? any tips or tricks i should no before i do this? thanks in advance for any advice you guys can offer!
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Old 09-15-2010, 03:59 PM   #2
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ive heard those studs tend to break off pretty easily, so be careful!
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Old 09-15-2010, 04:29 PM   #3
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Originally Posted by rick99601 View Post
ive heard those studs tend to break off pretty easily, so be careful!
thats what im afraid of because there is not much room to get an extractor in there if i do. im not one to take my truck to a shop for repairs but im a bit weary about doing this because of how the motor sits in the truck. thats kind of why im looking for feedback from others that have done it.
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Old 09-15-2010, 05:55 PM   #4
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Sometimes I wish I had an old truck for reasons like this. My buddy has a 78 f250 and theirs enough room to lay in his engine bay and shut the hood. On new trucks every things just cramed in there.
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Old 09-15-2010, 05:59 PM   #5
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Sometimes I wish I had an old truck for reasons like this. My buddy has a 78 f250 and theirs enough room to lay in his engine bay and shut the hood. On new trucks every things just cramed in there.
yeah i agree with that. o the joys of modern vehicles. makes it harder for a shade tree mechanic like me to fix stuff.
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Old 09-15-2010, 07:06 PM   #6
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I did it on mine and yes we broke off 3 studs two inside of the motor. We were able to pull them out though with a left handed drill bit thank god. it is a pain to do but it is do-able it probably took me about 5 hours going slow and figuring out what to do but its not too bad of a job. The hardest ones are the top two on the right. Just incase i would go to your ford dealer and buy all new studs for the side. We broke two just tightening them back in after and had to take it all back apart.
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Old 09-15-2010, 08:25 PM   #7
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i just developed the same problem, anyone installed headers on their 5.4??
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Old 09-16-2010, 07:44 PM   #8
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I put headers on mine and everything you guys have said is TRUE. It was a project that I had to take the truck into the shop. Broke 2 bolts, had to have the 2 holes oversized and the damn thing blows a gasket on the right side about once a year.

But before you put the header on, make sure they are FLAT(milled, plained, etc) otherwise they will always leak. It would probably be a good idea to, once a month or so get down there and tighten the bolts. Use anti-seize. Have a buddy and a case of beer close by..gonna need help
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Old 09-17-2010, 12:49 AM   #9
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i know i posted something about fixing exhaust manifold leak, because i didnt want to take it in to the dealership either. But now after working in the service dept. for about 2 months now, I wouldnt take in on myself. Nor do I want to pay the money,(and I get a discount), but it needs to be done. Mine is on the right side as well. I have a slight noise on the drivers side when cold, but learned that that is normal
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Old 09-20-2010, 10:17 PM   #10
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I'm looking at the same leak. Anybody know a ballpark figure for a dealer to replace the gasket (just one side).
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