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uzikaduzi 03-28-2014 07:07 PM

Passanger exhaust manifold leak
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:

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)
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 03-28-2014 07:17 PM

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 03-28-2014 07:36 PM

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 03-31-2014 11:56 AM

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 03-31-2014 12:04 PM


Originally Posted by uzikaduzi (Post 3399386)
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

Ran into the same issue...doing the replacement yourself is an absolute pain in the ass. 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 03-31-2014 06:35 PM

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

08silverbullet 03-31-2014 08:50 PM

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

uzikaduzi 04-01-2014 11:15 AM

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 04-01-2014 02:29 PM

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 04-01-2014 06:50 PM

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/

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