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post #1 of 22 (permalink) Old 07-20-2009, 05:43 PM Thread Starter
 
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Exhaust leak

On a recent trip my exhaust started leaking, the bolts that go from the manifolds to the rest of the exhaust let go. Well only one let go but I am replacing all of them because the old ones are almost completly gone between the flanges. My problem now is I can't get the portion that is left in the manifolds out. If I pull the manifolds off would a shop be able to get them out or do I need new manifolds as well? Is it even possible to remove the manifolds with the motor in place? The bottom bolts look like they are gonna be a P.I.T.A

Oh yeah it's a 97 f-150 4.6 v8

1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)

Last edited by Fordwheeler; 07-20-2009 at 06:37 PM.
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post #2 of 22 (permalink) Old 07-20-2009, 11:53 PM
 
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97 - 04 2v motors were known for the exhaust manifold studs letting go particularly at the rear of the manifold, the bottom bolts are a little PITA but it can be done with the motor in the truck through the wheel well , [remove the inner fender + wheel], soak the studs with penetrating oil for a few days it should make removing the manifold easier, and once removed the broken one you have should have enough to grab onto to get it out

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post #3 of 22 (permalink) Old 07-21-2009, 01:27 AM Thread Starter
 
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I'm soaking them in liquid wrench now then it's going to a mechanic. I'm in a little over my head on this one, especially since most of my tools are in storage. Thanks for the help anyway.

1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)
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post #4 of 22 (permalink) Old 07-21-2009, 08:33 AM
 
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yea mines got the same problem one reason i bought headers.... havent tackeled the problem yet maybe this winter sort of sounds like an old farm truck with the engine tick lol



2007 F350 6.0L Ext cab short box 4x4
2000 F150 5.4L Reg cab short box 2wd
?? always looking for a new ford project !
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post #5 of 22 (permalink) Old 07-21-2009, 09:48 AM Thread Starter
 
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Mine is extremly loud, scared me when it let go.

1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)
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post #6 of 22 (permalink) Old 07-21-2009, 11:42 AM
 
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When I did mine I sprayed them twice a day for a week and they came out no problem

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post #7 of 22 (permalink) Old 07-22-2009, 04:38 PM Thread Starter
 
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So after deciding to do it myself I am having a couple issues lol

I picked up a set of manifolds at pick n pull, the nuts (with studs still attached to the nuts) came off with a 13mm socket no problem or liquid wrench. But on my truck 13mm is too big so is 12 and 11mm too small. Tried 1/2" too big tried 7/16" too small. Am I missing something or do I just take the die grinder to the nuts then remove the studs?

Issue #2 Is there a trick to removing the manifold to collector studs from the manifold? (whats left of them anyway)

Thanks in advance

1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)
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post #8 of 22 (permalink) Old 07-22-2009, 11:44 PM
 
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Your manifold bolts/nuts may have rust and crap on them I do believe the proper size is 13mm when I did mine I used my bolt outs http://www.sears.com/shc/s/p_10153_1...2166000P?mv=rr they came in really handy for that job, and for the collector nuts I have an impact so it wasn't an issue for me but if you have to just cut them off or try a breaker bar

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post #9 of 22 (permalink) Old 07-23-2009, 12:32 AM Thread Starter
 
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I'm gonna try those bolt outs, thanks. The problem with the collector studs is that there isn't much left of them to grab on to. I'll take a pic and post it.

1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)
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post #10 of 22 (permalink) Old 07-23-2009, 12:39 AM Thread Starter
 
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1997 F-150 xl
1984 Honda XR200R (the toy)
2007 Honda CRF100f (the spare toy)
2005 Jayco Baja 10Y (the home away from home)
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