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Exhaust manifold broken studs
Exhaust Manifold broken studs

In a previous post there was a recommendation to check the exhaust manifold bolts as a maintenance item as they break with time/age.  So, I did and found that my 2003 T/K with 174,000 miles has two broken studs on the passenger side exhaust manifold.  I‘ve taken it to the local Ford dealership and they have given estimate of $1,500 to repair the passenger side exhaust manifold and $2,600 to replace both manifolds.  I’m not sure that the manifold is even warped just that the studs are broken.  The service manager recommended I change both manifolds out.  He says it is cheaper to change them out at the same time as they will both eventually warp.

Is this something other people have found needs to be done, change them out if they may not be warped?  With this many miles on the engine is it better to only change the passenger side?  Or has anyone found that they are going to eventually warp anyway and get both done now?  How about the price, does this sound reasonable?

JohnF
North Central Washington
2003 T/K
2003 TK
Re: Exhaust manifold broken studs
Reply #1 –
Sounds like a good time to buy a set of headers from Banks Power.   My set was $1800 and install was $1000.
Re: Exhaust manifold broken studs
Reply #2 –
Broken manifold bolts are common on other older/high mileage V10s and it sister engines. YouTube is loaded with broken stud replacement videos.
A Banks kit would also be my choice for manifold replacements too but you still have to pay for the removal and replacement of all the exhaust studs, not just the broken ones. More will break off.
Anyone mechanic only wants to replace the broken ones should be walked away from, get a bid based upon replacement of all the studs.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Exhaust manifold broken studs
Reply #3 –
I told my mechanic to replace all of the bolts.  Most of them were very corroded and would need to be replaced anyway.  At the same time I replaced all plugs and plug wires while we were there.  Only 40k miles, but 15 years old.   I did the Banks kit all the way to the back with all new exhaust.  They make a very well made system.  My mechanic has put in a number of them and he says they always fit well.  Expensive though.
 
Re: Exhaust manifold broken studs
Reply #4 –
Update:  Looked around for Banks dealers and found one local.  This shop did not recommend the banks exhaust manifold as they said I would have to replace the exhaust as well.  So for $630 they replaced all of the studs and nuts on the right side along with new exhaust gaskets.  Three of the studs had to be drilled out.  Sunset Performance and Repair in Cashmere, WA was the shop.   I do recommend them.  This is the first time I've used them and they appear professional and took Covid19  precautions.

JohnF
2003 T/K
2003 TK