Exhaust Manifold Stud Replacement Question

[JustRay]

I am looking into purchasing a used 2009-2010 Explorer with the V8. I hear that the V8 has a common problem with the exhaust manifold studs breaking off and have to be extracted. Instead of replacing these studs, can they simply be removed and replaced with a stronger grade bolt to simply prevent this from ever happening again?

Also, does the V6 have this problem in the 2009-2010?

 

[Explorer_PL]

I used stainless steel studs. But the problem is to get the old ones out first:

http://www.explorerforum.com/forums...ds-replacement-on-4-6-v8.416927/#post-3354454

 

[JustRay]

I used stainless steel studs. But the problem is to get the old ones out first:

http://www.explorerforum.com/forums...ds-replacement-on-4-6-v8.416927/#post-3354454

Stainless is rather on the soft side. I am thinking of just eliminating the studs all together and just using a high grade tough bolt instead. I am wondering if anyone has tried this.

 

[Explorer_PL]

You can, but they will rust eventually and you will be back in square 1. I have had mine for about 50k miles and all is good.
The problem is manifolds warping, and then snapping the bolts/studs.

 

[JustRay]

I was thinking a grade 5 or grade 8 probably would not snap. I could be wrong, but am wondering.

 

[tripplec]

Stainless, maybe better if they just stretch rather than snapping off since its more with hard steel being brittle. I read the linked post and saw the new manifolds but will that fix the problem or you starting from scratch and they'll warp as well (why too hot).

 

[Explorer_PL]

I expect the new manifolds to eventually warp again and start ticking. It's just a bad design.
The stainless studs should help removing them without breaking and avoiding drilling and tapping the heads which is a royal PITA.

 

[SixPonies]

This problem seems to be prevalent in mostly the 2007-2008 V8, and not the V6 at all. Not many folks have discussed having this problem in the 2009-2010 model years. Ford supposedly corrected this issue in 2009.

 

[JustRay]

This problem seems to be prevalent in mostly the 2007-2008 V8, and not the V6 at all. Not many folks have discussed having this problem in the 2009-2010 model years. Ford supposedly corrected this issue in 2009.

Very good to know! Thank you sir!

 

[Explorer_PL]

I doubt it. They fixed the sparkplug issues on 09-10 v8s, but not the manifolds. Most of the v8s suffer from that including F150 with 5.4, same design.

 

[Tech By Trade]

Father inlaw's 5.4 did the same thing. 2k later at the local shop. Funny enough my 4.0l snapped off the back stud as well. I was able to get the manifold planed by a buddy of mine and reuse it with gaskets. Easy job with the engine out to do the timing chains.

 

[JustRay]

I doubt it. They fixed the sparkplug issues on 09-10 v8s, but not the manifolds. Most of the v8s suffer from that including F150 with 5.4, same design.

What were the spark plug issues?

 

[Christobal65]

What were the spark plug issues?

06-07 V8 Explorer used the earlier version of 3V head which had a very odd/poor spark plug design to reach further into the combustion chamber. They are 2 piece plugs and are known for breaking and needing extraction using a special tool.

 

[Explorer_PL]

All 06-10 Explorers with v8 used those sparkplugs. What Ford changed was the on 08-10, they opened up the spark plug hole so there is more clearance. On the early models, the sparkplugs were almost touching the head and would get "carbonated" or welded together. When it was time to replace, lower part would break off and stay in the head. Newer heads had bigger bore from what I read.

 

[El Duque]

This problem seems to be prevalent in mostly the 2007-2008 V8, and not the V6 at all. Not many folks have discussed having this problem in the 2009-2010 model years. Ford supposedly corrected this issue in 2009.

I think it's still an issue with 2009+. I have a 2010 and it has the leaky manifold

 

[Larryjb]

Exhaust manifold bolts are an issue on GM's too. Kral has a pretty effective solution for them, but not for Ford's 4.6L

I will look into replacing mine this summer before they break.

 

[rah11h]

When I replaced my manifold last August, purchased a stainless steel stud kit from Amazon. I had three broken studs - two outside head - one was inside. Had to drill that one out. These stainless steel ones still look new. Here is the link to stud kit I purchased.

https://www.amazon.com/gp/product/B000CQ21CM/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1