02 XLT header replacement

[0two explorer]

I am looking at repairing what seems to be a very common problem with the V8 explorers. The passenger side exhaust manifold has a leak, not sure if it is cracked or if the gasket has blown through. Either way, the exhaust manifold has to come off.

On that note, is there a DIY write-up anywhere on this? I searched but didn't really come up with much. It seems that the best way to do it is to go from the wheel well side, by removing all the plastic shielding inside the wheel well, and gaining access to the bolts/studs.

Since they are rusted soaking them in some liquid wrench would be the first step I guess.

Any input/hints would be appreciated.

 

[Black Dynomite]

Your on the right track.

From Haynes
1 Disconnect the cable from the negative battery terminal
2 Raise the vehicle and support securely on jackstands
3 Remove the inner splash shield from the fenderwells (only do right shield on 2006 and later models)
4 Working under the vehicle, apply penetrating oil to the exhaust pipe-to-manifold studs and nuts. Also apply some to the EGR pipe fitting on the right exhaust manifold.

Left side exhaust manifold
5 2006 and later engines, detach the EVAP canister purge valve from the bracket and set aside
6 Remove the intermediate shaft from the power steering gear
7 Remove the exhaust manifold heat shield
8 Remove the nuts retaining the exhaust pipe to the manifold.
9 Remove the eight mounting nuts from the exhaust manifold.

Right side exhaust manifold
10 On 2005 and earlier models, remove the heater control valve bracket from the cylinder head and position the heater control valve assembly off to the side.
11 Remove the exhaust manifold heat shield
12 On 2005 and earlier models, disconnect the EGR pipe from the exhaust manifold
13 Remove the nuts retaining the exhaust pipe to the manifold.
14 Remove the eight mounting nuts from the exhaust manifold.

Installation
15 Check the exhaust manifolds for cracks. Make sure the bolt threads are clean and undamaged. The exhaust manifold and cylinder head mating surfaces must be clean before the exhaust manifold are reinstalled - use a gasket scraper to remove all carbon deposits.
16 Position a new gasket in place and slip the exhaust manifold over the studs on the cylinder head. Install the mounting nuts.
17 When tightening the mounting nuts, work from rear to front, alternating between top and bottom rows. Tighten the bolts in 3 equal steps to the torque listed in this chapters specifications. (15 Ft-lbs -- 20 Nm for Third Gens)
18 Remaining steps are reverse of removal. Use a slight amount of anti-seize compound on the threads for the EGR tube. (Exhaust pipe to exhaust manifold nuts torque spec is 30 Ft-lbs -- 40Nm)
19 Start engine and check for exhaust leaks.

 

[0two explorer]

^^^ Thank you for the info.

I am just worried that the studs will breake, and then I have to drill/tapp in a very tight space. That is never fun, and from what I have read it does happen.

I also got a quote from the dealer. $410 for the labor, not too bad IMO.

 

[0two explorer]

So, I have decided to take this exhaust manifold project on myself. No big deal, I will just soak the studs for about 12 hours and proceed to removing the manifolds.

While I am down there, is there anything else that I should replace? Not sure if there is anything else in that are, but I thought I ask anyway.