Ford exhaust studs

[JR]

JR,

This might be totally old news but Eric at South Main 9almost 12M channel views) has done several exhaust manifold and stud videos. MIGHT be a tip in here, maybe not.


But he also has done other engines where the stud breaks off nearly flush and he welds a nut on the broken exposed stud and gets success that way. Starts at about 11:30 min mark.

This might be all old news, but ain't much else going on right now.

Good luck,

Gary

Thanks Gary. The guy is good! A bit of a cowboy with the torches but good.
I've gotten fairly well versed in extracting. I've done the weld the nut to the stud on a few, the ones that break off in the hole I have this guy. It's been a savior.

https://www.nationaltoolwarehouse.c...A1rW19eQEWsGkUzFKeqYYaB0UIf7qI5BoC79YQAvD_BwE

 

[JR]

Speaking of welding, check out this little gem I acquired.

Stick and Tig capabilities, 220 150 amp, 110 volt 100 amp. It's also got an adapter for 30 amp rv style plug so I can haul this thing around camping and charge top rate to repair all those crappy RV frames

I'm super impressed with it. I've run alot of these inverter based suit case welders and been disappointed with most. Not this one. I just ran some 3/32 LH off a 15 amp outlet and it never tripped. Weld starts are seamless (where these things usually struggle the most).

I will run it off 220 most of the time but have always wanted one of these for their versatility and the deal was too good to pass on.

Happy camper

 

[DavidC]

Thanks Gary. The guy is good! A bit of a cowboy with the torches but good.
I've gotten fairly well versed in extracting. I've done the weld the nut to the stud on a few, the ones that break off in the hole I have this guy. It's been a savior.

https://www.nationaltoolwarehouse.c...A1rW19eQEWsGkUzFKeqYYaB0UIf7qI5BoC79YQAvD_BwE

That speaks volumes they make a tool especially for this. Maybe there's a problem

 

[JR]

That speaks volumes they make a tool especially for this. Maybe there's a problem

Oh it gets better. You can spend hundreds on an extraction tool. The differences are obvious where time is money but for a shade tree guy like me the Lisle tool is very functional.

 

[GCroyle]

The Ford WTF that gets me wondering is those extended reach plugs that break off in the head while removing. They are in a league of their own. Ugly.

 

[JR]

The Ford WTF that gets me wondering is those extended reach plugs that break off in the head while removing. They are in a league of their own. Ugly.

That was initially my biggest fear of a 3 valve 4.6 ownership. But I learned to change them often. OEM recommendation 100k miles....NOT! Every 50k miles seems to work well for me, and they are cheap considering the alternative. It's a combination of time and mileage, hot/cold starts that throw a wrench in the works. Even if a person was funds limited they could periodically R/R the same plugs with a fresh coat of Antiseize to prevent the inevitable nightmare.
Simply waiting is the worst thing one can do.

 

[Wayne M.]

JR, I’ve seen that lil Miller in action. Very nice.
Judging from how that stud broke down low in the head, and without being provoked, makes me think the manifold is moving too much. I didn’t watch the Ford guru. What does he say? I’d get a new log or have yours milled to clean up and the holes puffed a bit.

 

[Wayne M.]

That was initially my biggest fear of a 3 valve 4.6 ownership. But I learned to change them often. OEM recommendation 100k miles....NOT! Every 50k miles seems to work well for me, and they are cheap considering the alternative. It's a combination of time and mileage, hot/cold starts that throw a wrench in the works. Even if a person was funds limited they could periodically R/R the same plugs with a fresh coat of Antiseize to prevent the inevitable nightmare.
Simply waiting is the worst thing one can do.

I thought the early 5.4 were the real plug buggers.

 

[SRay]

We did have to buy a tool ($200+) to extract the broken spark plug from the worst spot, the last cylinder at the rear of a 2007 F150 5.4

 

[JR]

JR, I’ve seen that lil Miller in action. Very nice.
Judging from how that stud broke down low in the head, and without being provoked, makes me think the manifold is moving too much. I didn’t watch the Ford guru. What does he say? I’d get a new log or have yours milled to clean up and the holes puffed a bit.

Torch cowboy didn't really speak on the manifold much, he just replaced them. But they were alot worse condition than mine, wow.
He did say that aftermarket is junk and OEM is too expensive for anyone to be able to afford. He said he's seen aftermarket castiñgs with the inside nearly blocked off (probably from worn out molds) and no finish work. Kinda makes me want to stay OEM.

 

[sag2]

I replaced a manifold on one for a buddy a few years ago. I don't recall if it used a gasket or not, but could you double gasket it to provide a little "give" so it does not stress the stud as much?
I would not use a harder stud as you may not be able to drill it out if it did break. Or at least, drill on a new one before installing to make sure you can do it.