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Old November 25th, 2008, 05:14 PM   #1
joe_jeep
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Default 2002 v10 exhaust manifold leak

my 2002 superduty has had an exhaust leak at the manifold for a while. its not real loud. the factory exhaust manifold studs break, its common.

any one else on here have this problem? what did ya do about it?

im thinking of fixing it, but i know its gonna be a real pita!

ive talked to about 5 ford dealers about it had quotes from $350 to $2200.
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Old November 25th, 2008, 07:55 PM   #2
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I had a local shop do mine on my 4.6. Cost like 500 out the door with some misc parts. Do them all if you do them
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Old November 26th, 2008, 04:44 PM   #3
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If you choose to do the job yourself let me know. The hardware for this job is expensive and I can save you a ton of $$. Depending on how long it's been leaking you might consider having the manifolds machined flat again.
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Old November 26th, 2008, 08:27 PM   #4
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well for the superdutys they pull the cab off. and for the excursion they pull the motor. my dads 01 v10 has the same problem. we are goin to dig into it soon. it looks like a pain. he is goin to skip doin the manifolds though and get the headers.
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Old November 27th, 2008, 07:51 PM   #5
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you only need to jack up the engine an inch or two on the passenger side for 2 bolts.
all the other bolts are accessable through the fenderwell according to quite a few people on fordtruckenthusiasts.com. inner fenderwell must be removed. i was told to weld a small bolt to the center of the stud and back it out. if you have to drill some an easy out is an option but no fun.
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Old November 27th, 2008, 10:50 PM   #6
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i was just relaying what the dealer told me and my dad. we are definetly not pulling the motor what a pita. they charge an outrageous amount to.
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Old November 27th, 2008, 10:54 PM   #7
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I wouldn't touch them when I had my shop. To much heart ache to make a few bucks. I would recommend drillng out the holes slightly larger to compensate for expansion. The small holes and large amount of expansion is what keeps shearing the bolts off.
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Old November 28th, 2008, 05:12 PM   #8
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i was under the impression that because its a cast manifold and aluminum head they heat and cool at different rates causing them to snap over time. thats why my dad is goin to put headers on.
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