gvsu141

Hi,


I recently bought a 'new' 2008 F150 with a 5.4 and 97k miles to replace my 2005. I bought it for a good price knowing it needed the passenger exhaust manifold replaced due to the common ticking. I thought that I knew what to expect having done this on my 2005.

However, when getting ready to replace I found that both studs are broke off for the front cylinder on the passenger side. The problem is there is not any room to get to the studs to extract them due to the shock tower being in the way. If this was one of the rear cylinders, I could get to with a drill.

Does anybody have any ideas on how to get these studs out? If I can't figure anything out I may resort to finding a shop to do the work, but would prefer not to. I'm not in a big hurry, since I'll still have my 2005 for now.


I have attached pictures of top and bottom studs.

nyles68

I had mine replaced a couple weeks ago. Same issue. Mine was at a shop. When I went to pick it up they showed my the 5 (yes 5) broken studs and the amount of welding they had to do to get them out. Parts and labour it's was $1100 CDN and, in my opinion, it was money well spent. I'm very handy and do most of my own vehicle maintenance but that one wasn't a job I was ready to tackle.

techrep

iTrader: (1)

right angle drill ? mine is cracked also... I read may have to jack the motor for access..

Daks06FX4

Had my passenger manifold replaced last year, I left it with a trusted shop for a week. They only had to take out the starter and use a right angle drill don't remember if they had to jack up the engine or not, front studs were broke off on mine as well.

gvsu141

Thanks, I'll look into what it takes to jack it up.


There's only around 2.5 inches or so between the tower and the head, not quite enough to get a right angle drill in, as most look to be around 3" without counting the bit.

LiftedsKRew

I literally just watched a video on YouTube by fordtechmakuloco on how to remove those two broken studs. It's well worth the time as he explains how to get at them in detail. Don't have a link but a quick search will bring it up. Good luck.

vintageman

^that video is on an 99-03 model that the shock tower is not in the way as much, seen it a few times. It does show how to remove broken studs though.
OP, I had a shop do mine but I was around for some of the work, the starter was removed, the passenger side motor mount was disconnected and the engine was jacked up a couple of inches, remove the air cleaner assembly to get a little extra height and he removed the AC compressor. 1 stud broke flush in front, he welded a nut onto it and then used a wrench to take it out. By the way, he also broke a starter bolt and had to remove that as well. I ended up paying a little over $500 for the job that took him 2 days and am still glad that I had it done.
You can get a right angle drill attachment for a dremmel tool from Home Depot and try that, it will give you more room to try drilling if you do not have a welder. Good luck.
Tom

redknight1

these make for a great exhaust leak sound too

FST150

Here's a good video on this issue, he has others also

Check out this video on YouTube:

Redneckstone

if you take off the upper intake you can get more movement in jacking the engine up. on the second truck I this and it shaved 4 hours off my time due to having way more room.