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Old 11-15-2009, 11:17 PM   #1
pcmos
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Join Date: Sep 2003
Location: Budd Lake, New Jersey
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2003 Grand Marquis LS Exhaust Manifold

Unfortunately the rear top most stud on my driver's side exhaust manifold has rusted and sheared off for some reason. I discovered the problem because of an audible exhaust noise in the driver side footwell area. The missing bolt is causing an exhaust leak at the back of the manifold where it bolts to the engine block. I can feel that the top of the sheared stud is flush with the manifold flange which gives me hope that if I remove the manifold I'll have about 1/4" of stud left to grab back there. I might even be able to tack weld something onto it to twist it out.

I'm mostly curious to know if anyone can give me some tips on removing the EGR tube from the manifold. The location seems virtually impossible to reach with any combination of crow foot sockets, wrenches, extensions or swivels. I'm assuming I'll need to remove the steering shaft to begin with, at least that should make removing the manifold bolts easier. I'm just not sure how to get at the stupid EGR fitting. How would this be done in a dealer or workshop?
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