2004 F250 Exhaust Manifolds

Has anyone tried to replace the exhaust manifolds just to find that you've
got 7 broken studs between the two sides? Broken studs = drilling and
tapping? Removing heads so the machine shop can do it
(and buying new gaskets etc)?

Well, I propose a different solution. I did this on a Silverado a few
years ago, and it saved a ton of time.

First step is to remove the manifolds. I used a cutting torch and cut
off the old nuts/studs. :runaround:

Now, once the manifolds are off, you'll see this:
http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_133334.jpg

And now, you're thinking about the drill. But, this one might look easy
to get to, it's just the angle of the camera. But, the drill won't fit.
But...a wire feed welder will....

http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_133450.jpg

Now, make them look like this:

http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_133711.jpg

Don't be alarmed, the heads are aluminum. The studs are steel. The weld
will only stick to the studs. If it would do any damage to the threads, still
don't worry, because there is so much thread to lock onto beyond what
you could possibly damage. (By the way, no damage was done in my
particular instance)

Next:
http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_133806.jpg

Then:
http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_134248.jpg

http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_134256.jpg

After you let them cool for about a minute (only until the red goes away),
then use a socket wrench to remove them. Not an impact, just use a
ratchet.

http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_134618.jpg

And here!

http://img.photobucket.com/albums/v323/Slick_1/F250%20Manifolds/20141030_134700.jpg

I've done this on quite a few vehicles, and it works every time.

If you're working on something with cast iron heads, I don't recommend
this method (although I've done it).

Good luck!!

When I saw all that rust in the background of the picture, I had to scroll back up to see that you are in my general region of the country. Thanks for the post. Not having a welder for almost 20 years I forget how helpful they can be.