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Old 09-30-2011, 12:15 AM   #1
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V10 - broken exhaust manifold stud

I've got one broken exhaust manifold stud, rear most of LH bank.

I can't quite get a grip on it because it broke below the top surface of the header.
I assume it just broke from vibration/corrosion.

I was thinking I would try carefully drilling and trying an EZ-out on it. If I mess it up though, it means taking the whole manifold off which looks like a major pain on a van.

Any thoughts? I assume it isn't in there too tight, everything looks nice and clean. I guess maybe plan B would be try and slot it with something and use a screwdriver.

Any other ideas?

(yes all my posts are about rusted/broken stuff)
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Old 09-30-2011, 06:43 AM   #2
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Re: V10 - broken exhaust manifold stud

Hi;

I live in the land of rusted bolts.

I suggest trying the EZ out minimally with the expectation being that you'll have to drill the whole bolt out and re-tap it or put in a Helicoil.

The last thing you want to do is break off the EZ out in there after having effectively drilled out a large percentage of the bolt.

I would also heat the living you-know-what out of the area the stud is stuck in before attempting extraction. That should help loosen it up. Clouds of smoking WD-40 applied to the area seemed to help too.

Take your time and good luck.

Regards,

Gavin
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Old 09-30-2011, 08:34 AM   #3
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Re: V10 - broken exhaust manifold stud

A little more research on Ford Truck Enthusiast forum shows this is a very common issue, and that people replace them with stainless studs or M8 x 1.25 x 35 flanged stainless bolts. I am leaning to the bolts because you don't have to worry about nuts seizing to the stud, and given the limited space on the van, would make it easier to move the manifold around.

Right now though I am not planning on fixing all of them just that one.

I worry about getting heat in there, in am never good about directing it to the right area and also there is wiring, hoses etc.....
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Old 09-30-2011, 04:42 PM   #4
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Re: V10 - broken exhaust manifold stud

Is the manifold leaking? If not, I wouldn't worry about it. The manifold is rigid cast iron and has only minimal pressure on it. Many an exhaust manifold has gone for year with a missing or broken stud and had no problems.

Mike
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Old 09-30-2011, 05:13 PM   #5
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V10 - broken exhaust manifold stud

If you are going the easy out route be sure to center punch the stud first and then drill a small pilot hole. That will help keep the EO drill bit from wandering as you drill.


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Old 09-30-2011, 06:28 PM   #6
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Re: V10 - broken exhaust manifold stud

Drill it with a reverse pitch drill bit. It may come out on the drill bit, and not need the EZ out.


Mine was broken when I got the van. It never leaked. I never addressed it until I put the Banks PowerPack on.
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Old 09-30-2011, 10:25 PM   #7
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Re: V10 - broken exhaust manifold stud

Quote:
Originally Posted by Ford_6L_E350
Is the manifold leaking? If not, I wouldn't worry about it. The manifold is rigid cast iron and has only minimal pressure on it. Many an exhaust manifold has gone for year with a missing or broken stud and had no problems.

Mike
No leaks.
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