And the carnage begins....

[07EddyB]

Can you try to tap on the edge of the broken tools in a counter clockwise direction with a very sharp center punch?
Its worth a try at this. Since the stud is loose, it might start to back out.

Know anyone with a buzz box? (Portable mig welder)

I'm afraid it's worse than that. The hole went in at an angle and from the angle I was viewing it at I didn't realize that it went to the threads. So I think I was catching part of the head with the extractor. I got a better angle and tried to start another hole but there just isn't enough left.
Stupid question - is the Fol-Pro gasket set for both sides? I've got eight individual gaskets and I assume I'm only supposed to use 1 on each port. Is that correct?

 

[Bill MacLeod]

Yes on the gaskets, singles for each port.

Is there room for a good welder to spot maybe a fender washer onto the stud or a piece of the broken tool?

Do you know any local Ford techs or have a good relationship with any local Ford dealer service department?

 

[07EddyB]

Yes on the gaskets, singles for each port.

Is there room for a good welder to spot maybe a fender washer onto the stud or a piece of the broken tool?

Do you know any local Ford techs or have a good relationship with any local Ford dealer service department?

Thanks - that's what I figured. No good relationship at the local Ford dealer although they've treated me well in the past. The Ex hasn't been to anyone since warranty ended - and it only went once then. I look at it this way - when I started only 6 bolts were holding the manifold - now there are 7. So that's an improvement. The old head was warped - we'll see how long it takes this one.

 

[Bill MacLeod]

Eddy: I just spoke with a Ford tech about your situation because I knew that they call someone local that has a mobile operation. There is a service all the local Ford shops use for stud/bolt extraction, 3v spark plug extraction, helicoils on the 2 valves, etc. Likely other shops that have similar work.
They use a diamond tip tool/drill bit that literally smashes the harden broken bits. Then they drill out the stud and chase the threads. After that the dealer tech do the rest of the work. They charge the dealer something like 100 bucks a hole.
Don't know what is available in your area, but would be worth the time to see what your dealer could offer for service.

 

[07EddyB]

Thanks for the info Bill. I'm sure I'll have to go that route eventually. I have too much going on right now to take it somewhere so I hope this holds up for a while. When you think about it, I'll bet there are quite a few Explorers out there running 7 studs.
I've got the new manifold in - took some time to get it worked into the opening - had to remove the studs that I had put in to give me enough room. Also removed the top bolt from the flange to get it past the pipe. So I've been installing studs and gaskets at the same time. To top it off, I dropped a stud down between the heat shield and the manifold. Had to take it off to retrieve it.
Hope to tighten the manifold up tonight and get the engine mount reconnected. Maybe get the starter back in - not going to push it though.

It's been a soul crushing day and I'm ready to step away from it again.

 

[Explorer_PL]

It may be too late for that....
Did you put a straight edge to see if it's warped ? If it is, I would get a new one, and if you didn't want to invest and you want to reuse it, on the side where it's warped the most, double up the gasket. Maybe double it up by the missing stud anyway. But the truth probably is you will be much better off already with the new studs and you'll get many more years on 7 studs. I bet you most of the F-150's and Explorers run on 6-7 studs anyway.

 

[07EddyB]

It may be too late for that....
Did you put a straight edge to see if it's warped ? If it is, I would get a new one, and if you didn't want to invest and you want to reuse it, on the side where it's warped the most, double up the gasket. Maybe double it up by the missing stud anyway. But the truth probably is you will be much better off already with the new studs and you'll get many more years on 7 studs. I bet you most of the F-150's and Explorers run on 6-7 studs anyway.

Yes - it was warped. Funny thing - the high spot seems to be the second port from the back. The manifold would rock on a flat surface from that flange. Yes - a new one went on. It's the Dorman - for this effort I wasn't going to put the old one back on. Also used the stainless stud kit and hit the studs and the screws with some nickel antiseize left over from the plug job.
It wasn't the best possible outcome but it is what it is. I'll have it running in the morning. Manifold is tight - engine mounts reconnected - wanted to do that tonight before I forgot them..
Many thanks to you and Bill for the help - and kudos for pulling this off yourself. Not an easy job by any measure.

 

[Bill MacLeod]

Torque the stud nuts from front to back. Do a heat cycle before you put the liners back in place, then check torque when its cooled down. If you have a couple of M8 hex nuts kicking around, double nut the bottom of #1 and both studs on #2.
Fingers crossed on this end hoping in works out for you.

 

[Explorer_PL]

Then I am pretty sure it will be quiet like new. Good job, I know it cost you in extra grey hair

I recall one side was easier than the other. Take a break and think about the other side in near future.

 

[07EddyB]

Then I am pretty sure it will be quiet like new. Good job, I know it cost you in extra grey hair

I recall one side was easier than the other. Take a break and think about the other side in near future.

This (passenger) has to be the hard side. If the driver's side is harder I'll just set the Ex on fire. Almost back together. Back up top now in the engine compartment. Will do a final check and start it within an hour.

 

[tripplec]

No Pic's?..... Could be up or the an Award at TIFF or one of the other movie award venues!!

Staring the one and only 07EDDYB and his faithful Explorer (not sure about faithful though)

LOL

 

[07EddyB]

No Pic's?..... Could be up or the an Award at TIFF or one of the other movie award venues!!

Staring the one and only 07EDDYB and his faithful Explorer (not sure about faithful though)

LOL

I don't have an online pic service so I can't post pictures here. I could have made a movie I guess but starting around day 2 it would have earned an R rating for explicit language. I don't think You Tube would even post it. Everything is ready - waiting for my wife to get home to run it - would like to be on that side watching.

 

[Bill MacLeod]

#5 & 6 on the left side are just as difficult to access as #1 & 2. With the nuts of the studs of the p/s pump, you can slide it down some to give better access. Important once again to lift/tilt the motor as far as possible. #7 &8 are cake.

 

[Bill MacLeod]

#5 & 6 on the left side are just as difficult to access as #1 & 2. With the nuts of the studs of the p/s pump, you can slide it down some to give better access. Important once again to lift/tilt the motor as far as possible. #7 &8 are cake.

 

[michael loibl]

You are a better man than me! I would've been crying like a little girl! I hope it all goes smooth from here and you are rewarded with a great running truck for your efforts.

 

[07EddyB]

Just started it - it's loud as hell. Sounds like its coming from the front of the manifold.

 

[07EddyB]

OK - second attempt has yielded good results. Since I posted that it was loud I've actually taken down the manifold and changed the gaskets - put it back together - and took it on the road for about 15 minutes. So - what happened? Here's the story - I thought about this yesterday when I was putting the manifold back on. Remember those Fel-Pro gaskets I was asking about? Well - it's a separate gasket for each port. I don't have a stud at the top on one port.
You see where I'm going here?
I was being very careful when I put it back together to line up that gasket but it must have slipped at one point. So I did what I should have done yesterday - put the gaskets on that came with the manifold. They look exactly like the OEM and each gasket covers two ports or four studs. That way I know I have it lined up correctly on the one stud port.
That seems to have done the trick - there is still some tick but honestly it could be coming from the drivers side. All the other engine noise are louder than the exhaust so that's progress I guess.

 

[tripplec]

Hooray and the saga ends, I think...

 

[07EddyB]

You are a better man than me! I would've been crying like a little girl! I hope it all goes smooth from here and you are rewarded with a great running truck for your efforts.

I was tested - that's for sure. I thought I was going to be sick when I started it after 3 and a half days of work and it was extremely loud. Something was wrong - I couldn't drive it - and I had to drive it to work tomorrow. I don't even want to try to describe how I felt at that moment. I really just wanted to give up but I put my big girl panties on and dove back in. It's actually amazing how quickly I unbolted that manifold and swapped the gaskets out. I didn't have to take everything else back off because the manifold wasn't coming out this time. Here was the fun part - I was under it with a ratchet trying to get to one of the studs when my ratchet came into contact with the hot on the starter. Yep - I wasn't dropping the starter so I forgot to disconnect the battery. Got a little light show and then had to wonder for the next hour or so if it would start or if I had screwed something else up.
Now I get to be the guinea pig - how long will it last? Can 7 studs perform? For reference, I'm at 99.8K right now.

 

[PotatoExplorer]

It might not have been the success you were exactly looking for but I'd say all in all it was a success. If anything, a major learning experience, no? Again, major balls, EddyB, and major props!