uzikaduzi

so I know this has been talked about over and over here but i have a a leak at the exhaust manifold and was looking over and looking over and looking over what's involved in changing it out and i found someone mentioned an 8year/80k mile warranty on emissions related parts and i have never heard of that so i found this:
http://www.fordservicecontent.com/Fo.../06frdwa5e.pdf

this is specific to 2006 but they have them for a number of years and it confirms the 8/80k mile emissions warranty... on page 13 it says the following are covered:

List of Parts Covered by Emissions Warranties For Cars, Light
Duty Trucks and Heavy Duty Vehicles
• Air Flow Sensor
• Air/Fuel Feedback Control System and Sensors
• Air Induction System
• Altitude Compensation System
• Catalytic Converter
• Cold Start Enrichment System
• Cold Start Fuel Injector (1)
• Controls for Deceleration
• Electronic Ignition System
• Exhaust Pipe (Manifold to Catalyst)
• Electronic Emissions Control Unit (ECU)
13
• Electronic Engine Control Sensors and Switches
• Evaporative Emission Control System
• Exhaust Gas Recirculation (EGR) System
• Exhaust Heat Control Valve
• Exhaust Manifold
• Fuel Filler Cap and Neck Restrictor
• Fuel Injection System
• Fuel Injector Supply Manifold
• Fuel Sensor (1)
• Fuel Tank (non diesel only)
• Fuel Tank Pressure Control Valve (1)
• Idle Air Bypass Valve
• Ignition Coil and/or Control Module
• Intake Manifold
• Intercooler Assembly - Engine Charger
• Malfunction Indicator Lamp (MIL)/On-Board Diagnostic (OBD) System
• PCV System and Oil Filler Cap
• Powertrain Control Module
• Secondary Air Injection System
• Spark Control Components
• Spark Plugs and Ignition Wires
• Synchronizer Assembly
• Throttle Body Assembly (MFI)
• Transmission Control Module (TCM)
• Turbocharger Assembly
• NGV module (Bi-fuel/CNG)

now technically it looks like i may have blew the gasket but i'd imagine the manifold is likely warped. what do you guys think my chances are for getting this fixed under warranty?

screamineagle

Well exhaust manifold is on the list so I would assume it's covered. My 06 has the same issue. Too bad I'm at 190,000!

uzikaduzi

I'm hopeful but if i was a guy hired to review warrenty claims and keep warranty costs down I'd say...

the gasket ruptured which is not covered since it's inbetween the manifold and the heads... to replace the gasket it's x # to change the gasket + x amount per stud breaking. if the manifold is warped, we'll replace that (and only that) free of charge

uzikaduzi

wow, just got a quote from the dealer... nothing is covered and they want $1033 plus $230 per stud that breaks. looks like i'm gonna give it a shot myself

blackhawk51

Ran into the same issue...doing the replacement yourself is an absolute pain in the ***. I ended up taking mine to a dealer and got it all done for $768 including 4 broken studs. Shop around a bit and see if you can work out a better price. The price I paid was the best in my area of the 4 dealerships within 30 miles. Good luck - I know how annoying this issue is!

uzikaduzi

second quote from another ford dealer... $500 + parts if no studs break... hourly rate for stud removal @ $110 an hour if they break

08silverbullet

Check the local exhaust shops sometimes they'll cut you a deal

uzikaduzi

i started soaking the studs in kroil last night... I'm gonna do it once a night for a week and try it myself

putermech

I replaced mine last summer. I used a can of PB Blaster everyday a week prior to removal. I had no broken studs. Besure to remove the sway bar for extra room.
Also have some semi-fine sandpaper to remove the old gasket. This project was the toughtest I have ever done. Good luck.

uzikaduzi

anyone ever use acetone and atf as a penetrator? I've read good things but I'm nervous... pretty sure acetone on the wrong parts is bad news where as kroil or pb blaster are relatively safe/