V-10 manifold bolts broken

[citydweller99]

Have a question about fixing this problem for good. I have a lot of bolts broken and a couple of them are even with the manifold. The truck is a 2001 F-250 and only has 60,000 miles on it. Some one suggested replacing the manifold with a header....Any suggestions? I plan on keeping the truck a while and do not want to do this again. Thanks

[rhandwor]

Soak them with P-B Blaster for a few days. If you have enough to get a hold of with channel locks try to use a stud remover or channel locks and get them out. You can always remove the head and take it to a machine shop to get them removed. Use new grade 10.9 bolts or studs and use a torque wrench.
Ask your local machine shop for their advise. Some use a thick washer and a mig welder to weld the washer to the stud then weld a nut to the washer and remove them. I never had much success on aluminum heads I got the studs out and had them fill welded using a mig welder with aluminum wire. Filed off and used a gasket and drilled a new hole.

[citydweller99]

Thanks for the reply, Not looking foward to this big job at all.

[rhandwor]

If the head is cast iron with 3/8 inch bolts I drill out the bolt with a 5/16 inch drill bit and retap with a 3/8 inch tap. Center punch the bolt first. I think they went from 3/8 to 8mm bolts is why they all broke with an aluminum head. I have drilled one or two and used 3/8 inch bolts some people use heli coils.

[yotermanic]

Don't Triton exhaust studs suck? I have had some good luck slotting them with a dremel and turning them with a power driver (the screwdriver-looking tool you hit with a hammer). Sometimes I get a little over-zealous with the dremel and get some of the head, but have observed no ill effects to date. Also, Ford has revised studs out, I usually helicoil to original thread when I end up drilling them, then I don't have five different sized sockets out next time I have to remove the manifold...I don't see how headers would help your problem, but if you want them, now would be the time. Good luck with it!

[citydweller99]

Yep going to helicoil them and looking at stainless steel bolts. I really don't want to do this again. Thanks again