Ford F-150 Exhaust Manifold - Remove and Replace 

Thanks for the video, I just did this on my 2000 5.4 F150. Lessons learned/specialty tools used by DIYer: -Irwin bolt extractor set 3094001 removed all nuts -Performance Tool stud extractor W83203 removed studs the best -Lisle stud remover 19250 removed some studs, I prefer the PT stud remover -Dorman screw grab helped tools remove some misshaped fasteners -I bought new stainless studs/nuts from MSTC -the MSTC studs don’t come with down pipe bolts, get down pipe fasteners from Dorman/Advanced Auto -I used OEM manifold and gaskets -I removed the starter solenoid for better access to a few bottom studs and 1 down pipe bolt -preventative maintenance, I replaced the starter solenoid since I had the original off -preventative maintenance, spray the downstream O2 sensor with proper cleaner since it’s right there with manifold out -preventative maintenance, spray Sea Foam down exhaust pipe towards catalytic converter to clean deposits (truck will smoke for a few minutes upon start up as deposits burn) -with truck on tall jack stand, I was able to do most of the work on a comfortable stool -creeper is nice for removing starter solenoid and 1 down pipe bolt -if you can’t get the top left stud out by down pipe, watch video by Warzone The Collector

I have an old Ford that needs work almost constantly. And I've always been amazed that local mechanics can work on it because everything is rusty. Now, after watching a few of your videos, I have a better understanding. They can work on them and still make a buck because they know what they're doing and they have the equipment. Me? Takes me hours and sometimes days. No way would I make any money. To do what you did here would definitely take me days. Don't have the knowledge gained by experience or a good teacher. And tools? My favorite frozen rusty nut and bolt getter-offer is a 4 foot long steel pipe slipped over a 2 foot long 1/2 inch breaker bar. A torch? I have a little propane torch but I think all of the canisters are empty. My usual cutting tool is a 4-inch Tool Shop angle grinder with a metal cutting wheel on it. And I've got some tin snips.

23:11 "I don't know if I can get it in all the way? That's always been my problem!" Made me spit out my coffee. Merry Christmas to you, Mrs O, and the rest of the family.

I think we need to clone Mrs. O because I say again she seems to be the coolest wifey I have ever seen. You sir are a VERY LUCKY MAN!!!

If you ask me Eric a healthy combination of diagnostics and wrenching makes yours the best automotive channel on the RU-vids. It can be helpful to see how you approach a difficult job or solve problems you come up against while doing a mechanical job. You probably have a pretty varied audience of DIY'ers, advanced DIY'ers and working mechanics, techs who like both! I actually can't believe you aren't already on 100k subs. Thanks for all the great vids this year. Merry Christmas to you, Vanessa, kiddos and all at SMA.

It's good to see someone uses more break cleaner then me. I'm 60 and you teach me alot.

Definitely the best automotive mechanic I have viewed on RU-vid. Excellent technical Diagnostics skills, excellent nuts and Boots mechanic meaning he has the tools, knows the tools and knows how to use not abuse or force the tools to get the job done.

Just put new manifolds on my bought new 03 F150 Lariat Super crew. 5.4 litre/302 Triton, 79K KM'S/50,000 Yankee miles. Passenger side manifold rusted through at the front cylinder and started that terrible racket for the 1st minute every time I started it, would go away after a minute, but return every time you stepped on the gas ! One of those sit in the garage and corrode trucks. We got salt too !. Rest of the truck is like new. First job ever on this tr uck besides a battery and tires was calipers, pads, rotors 6 months ago. Your video's are excellent Eric and learned a lot with your diagnostic stuff ! You get North of the border look me up, take you and the bride for a ride in a Mahogany barrel-back along the river with a 350 Mercruiser Dad and I built. Upper NY is not far away and the torches are always hot !

Rusty and Crusty videos....the good stuff for many Gearheads .Keep em' coming Eric O.

One of the best repair videos you've ever done, Eric. This is why I support your channel. You actually get in there and do the work. Holiday Cheers to you and yours.

Good afternoon to you all at your place. I am in the North Island of New Zealand. I have have learnt a lot from your videos. Not just how to take care apart but also how to use different types of equipment. I have have been a hobby mechanic for many years and thanks to you and others I am still learning. Well done!!

This fella knows his stuff. Excellent personality. Priceless. And excellent information.Thank you.

Nuts and bolts, diagnostics, another day at the shop, working with Ivan, we love it all! Thanks Eric!

I was LMAO! 😂😂" will zip these right off ". I love all your videos Dr O! I just don't understand what it's taking so long to have more subscribers,you should've been over 100K by now. Diagnostic videos are challenging the mind,but I enjoy watching you turning wrenches too!

I like the use of the air hammer, great idea to bust the rust, That would of saved me alot of broken bolts and studs!

The alignment/mechanical shop we use at work just did one of these this week. From what my boss was saying it took one guy a couple of days to complete. He broke several of the studs off in the head. He obviously didnt't use your skilled blowtorch technique to remove most of the nuts. Amazing work Eric!

Thank you for doing this nuts and bolts video. The tip using the torch to remove the nuts was perfect!! Been welding for 30+ years and have never used a welding tip as a cutting tip...

thank God a repair video lol I love the nuts and bolts stuff

Learned a new trick ! ASA Master w/35+yrs and I've never seen the brazing tip used for cutting. Must live a sheltered life. Tried it myself today & makes a nice neat little cut. THANK YOU. One tool I use on this type of stuff though is the Speed Blaster. The little sand blaster cleans up whats left of studs, brake fittings, etc for cleaner extractions.Helps break the rust bonds & the penetrant gets in better.

Watching Eric O remove the old Form exhaust manifold again to hear...”that one’s loose, that what I like about Ford.” Easiest vehicles to work on, always leave their bolts loose and most Fords come with parts tray. Like they expect future work. Thanks again Eric O for leaving archive entertainment.

LOVE WATCHING YOU WORK STRAIGHT FORWARD AND DONE. YOU MAKE IT LOOK LIKE I CAN DO THAT, MAYBE BUT A COUPLE DAYS LONGER....LOL

Clearly not your first rodeo! Watched a bunch of your videos now and from what I've seen you make this stuff look easy. Sometimes too easy , makes a diy guy like me think if he can do it I can do it .....next thing you know cars on fire wife's screaming and I'm sitting there like Eric o made it look so easy lol Anyway I think you do a great job and thanks for sharing!

This is the best kind of video! Most of us don’t have all the scan tools and scopes, I just like to watch you fix things and thank God I’m in the south. Love the videos, man, keep it up

Very cool to see you cut those nuts off before trying anything else. I've spent many hours before fighting those rusted suckers off the bolt studs. I have a new method now for removing rusted manifolds. Thank you, for another great video presentation. You are the best channel on youtube, "hands down". I'm excited to see other people recognize you. You are teaching people many new things in life's mechanical world. I know sometimes it can be a hindrance. At least it's NOT a reality TV show. That can get very invasive to your personal life. Keep up the great work you do! Thank you, Matt Eaton, Boise Idaho mechanic who appreciates another good person.

*@**11:12* Nice torch re light. Pretty slick there, young Fella.

Nice trick using the welding nozzle to heat then cranking up the O2 ... I’m going to try that one out.

Love the siren just as he lights the torch.

This video is like some of your first videos. Rust, crust. air hammer and a torch ! Good work !

That's not a manifold stud. That's iron ore.

Surprisingly nice weather for December. Haha!! Merry Christmas to you all at South Main Auto. Thank you for all the awesome videos.

Your word terminology is second to none Eric O Watching you fix things ya absolutely fantastic and as usual Mrs O steals the show lol 😆

Hello SMA and good morning Mr. Eric and Mrs O , it’s 6-22-24 , at 7:32 am Saturday morning in east Texas , hope yaw have a wonderful day.

Cut those studs off and whack that thing out of there it looks like it was laying next to the titanic all these years!

You make that stuff look easy, Awesome vid Eric.

I just did this job on my 5.4 triton and I was told to NOT use the paper gasket that comes with the aftermarket Chinese manifold and instead buy a much more expensive steel gasket. The paper can blow through. Glad I did the job with a quality gasket. Also used a thin coat of high temperature gasket maker on either side of the steel gasket to fill any imperfections in the head and manifold. Also used stainless steel bolts from a hardware store instead of the steel studs. That is a absolute must. It is also a good idea to retork the studs after 500 miles because the gasket might compress . Also painted the manifold with high temp paint prior to installation. Anything to prevent rust.

"RU-vidrs"--right in the middle of you creating none other than a RU-vid video, hahaha. I was born and raised in the region south of Ithaca, NY, so I know those stomping grounds real well. While it would be interesting to stop by and meet you when I am up in NY state visiting family, I can't imagine the hassle it is to have complete RU-vid strangers coming by and interrupting your work. Bet you didn't see that coming the first time you clicked the video upload button! You are pretty much my go-to auto repair channel. Clever, funny, logical, and a very broad base of knowledge. A fairly rare combination. Keep up the good work and do more tractor videos (I worked on farms growing up and have a homestead with my family).

For really pitted exhaust ports, clean the gasket surface (brake cleaner of course), and then spray the exhaust gaskets with copper spray. It'll seal in imperfections.

Dewayne and I were waiting for this video. Thanks for posting it and taking the time to talk with us. Rob.

I have done countless ford exhaust manifolds on the aluminum heads. The secret is to let the engine get to operating temperature. Im usually pretty good at getting the old studs out of the head without breaking. I have a stud extractor tool that looks like a drill chuck. Its one of my favorite tools. Before trying to get the stud out, hit them with a hammer up, down, left and right. I once even used an air hammer to completely remove a manifold and was able to get all the studs out without drilling!

Three years later, but a comment that may save you some aggravation in the future. A few years back when Acetylene became hard to get and the price jumped, I thought of making the switch to propane, by discarded that route because it doesn't get as hot and I'd have to purchase tips for three torches and a few new tanks. I own my tanks, and t ruled out purchasing three new ones. I had been looking at plasma cutters and figured I'd give it a shot for my cutting needs instead of a torch set. I'm happy to report that the Hypertherm Plasma cutter works great for blasting manifold nuts and the best part is very little heat generated, and the cost of consumables was less than 1/4 of the cost of an oxygen acetylene torch set tips and gas refills. Unless I have something that needs heating before bending and welding, the plasma torch has replace the OA torch for my cutting needs.

wouldn't want to do this without a lift and a torch .

Man I feel so privileged to not have to deal with the crap you salt belt guys see. Only time we see rust remotely close to that is on pickups that spend lots of time launching boats in salt water.

Watching Eric O's videos are just so therapeutic!

Bestest darn mechanic this side of the Pecos.

I enjoy and learn with your videos , Merry Christmas to you and your family , keep the great work . Your Mrs . is great too.

Hey thanks Eric! The electrical diagnostic videos are pretty interesting, but yeah, I like the regular repairs a lot as well.

Hello Eric I know this is an old video just saw how nice you were to your you tube fans I was watching bad chad the other day and he literally threw some fans or customers out of his shop because he was recording a video and left it on there while he was dogging on them just appreciate your videos and keeping it family friendly keep up the good work.

rumor is next door to south main auto is a brake clean museum.

Eric, your a great tech best on RU-vid, Eric the Car Guy is way out in space now a days, keep it coming.

I liked the moment you started cutting with the torch an emergency vehicle with siren goes by. I enjoy your videos.

Thanks! The diagnostic videos are very interesting, but most of us (I assume) don't have those tools, so these type of mechanical videos help me more.

I like everything SMA!. But as a fan I'd love to see an engine build!

Hi Eric great video as always .Merry Christmas to you and your family. Just wanted to let you know I appreciate the time and effort in making the videos. Great to watch your channel from here in Scotland. Keep up the good work.

Bro, I like the nutz and boltz and the diag videos. Even if I don't have a high dollar scan tool, knowing the theory behind what your doing and why is priceless learning.

I wish there was a shop like yours and I wouldn't be fixing my own vehicles. Your customers are lucky to have you‼️

"Whoa - wrong hole!" - Gold.

Love Nuts and Bolts Stuff, more please!!

I like the diagnostic videos. I am just a home mechanic but I like doing it because I enjoy fixing my own stuff and it saves me money (if I don't screw up). I find that the diagnosis - know WHAT to fix - is the hard part. Actually swapping parts can sometimes be tricky but most folks with some tools and mechanical ability can do most stuff.

"wiped the floor with me"... & "I don't know if I can get it in all the way? That's always been my problem!" Made me spit out my coffee as well...New sub just for those quotes. Keep the vids coming !

great video eric. I've changed many of these manifolds and this is my technique as well. works like a charm. I'm going to start a repair channel with my shop in the next week and was wondering what kind of camera do you use. I have a go pro but I don't know if it will work well

You make things look so easy, and we do like some nuts and bolts stuff, but the electrical are fun to :) happy holidays

This gave me the motivation to remove mine (I have heat shielding that has broken loose and rattles to hell and the only way to remove is by removing the manifold). Thanks as always Eric!

I think I enjoy watching you remove rusty and broken off nuts and bolts than anything else you do.

With all the "just dropped by to say hi!" people thronging the place, he'll have to move the shop to an "undisclosed location" so he can get any work done.

That flame wrench works good on those nuts ! Maybe ChuckE2009 has a spare welding coat ? Of course the arms would be about 6" too long !

Really gr8 to see a Real world repair with crusty rust there to hamper you at every turn. And to top it off,limited access. Good honest work in a Real environment. Great instructions. Thanks for the lesson.

I was thinking about this video the other day. And I realized there was zero use of penetrating oil in this video... Like a boss!

This one must have been in the vault for awhile. No snow everyone in summer clothes

"I should get a glove" *doesn't get glove*

I'm in CT and it is literally impossible to find a good mechanic. Period. You cannot find one who does even a quarter of the caliber work you do. No smoke blowing or sucking up just honesty. I wish you had a shop near me. Its 6hrs from me to you. I might make a pilgrimage at some point. No lie.

Hey great video . Tried to follow Makuloco suggestions on my 2010 4wd 4.6 3v crew. With No torch in the Boston area. Wow What a real PITA 4 days on and off to finish I was lucky in that studs did come out. Of course Engine had to be lifted a few inches to get and access. Chisels, Sawzall 3 cans Wd40 and 4 lbs of skin...Just the worst job I ever had to do in my life hands down. And i only did the leaking stud broken passenger side Still want to do the drivers. Yea I used the Dorman Manifolds and Gaskets. Did save the OEM gaskets though. Stainless Stud kit w/allens on amazon as well. If you feel frisky Try a 2010 man video I would enjoy a laugh seeing if you fight it too Or perhaps you have already. The red wrench I do miss alot as I have messed with corrosion. Done on jack stands... I must me insane.... Thanks to all who participate here great knowledge and personalities

finally some good o'l upstate ny rust love it!!! great video eric keep up the great work and merry christmas to you the family and a happy new year! funny too! :-))

hey Eric what is the brand name of those stud extractor kit? did not see them on your Amazon store

Same as my Expedition. It busted of 2 studs with the block. I also used an aftermarket EGR tube and it wasn't bent right. That friggin tube was almost the hardest part of the project. Also one of the aftermarket manifolds was so crusty I made the auto parts store order a new one. It looked like it came out of the mold and was never cleaned up.

Wishing a Merry Christmas and a very happy and prosperous new year for the crew at SMA. Good video Eric. I enjoy both types of videos. I learn a ton from your diagnostic videos.

41:59 "Oh it's so hot! I should get a glove." *proceeds to grab the metal with bare hand*

You can't trust them sneeky RU-vidr's. Stuffing their pockets from the candy bowl and denuding you of complimentary matchbooks. They're a menace to society! Anybody need a light?

Changed cracked exhaust manifold on an F150 I used to have. I think it was around 10 years old at the time. A bit of penetrating oil, unbolt the old and bolt on the new. Grateful not to live in a salt area.

Well I'll say out of all the mechanics o know and have seen do work. .. btw I do all my own work. I cringe every time someone tells me they spent $$ on something like plugs and wires or a bushing here and there. But I just wanna say u seem to be the most honest and ine of the best mechanics I've ever seen

Eric O. > Eric the car guy

Word of caution: Sometimes the 'ole reach around can get you a firey nut in the face. And now you know and knowing is half the battle.

Well done, Dr. O. A quick suggestion especially for your own vehicles, is to spray the mechanical parts down periodically with one of the many marine products such as Salt-Away. They are designed to remove salt from engines and running gear in marine applications for vessels operating in salt water. Work well on trailers, too, greatly extending the service life by neutralizing the corroding effects of salt on various kinds of metals.

I was surprised that you didn't wear long sleeve shirt to protect your arms burning from the sparks. I would have used thread and tied the gasket to the manifold when installing it. That way you aren't fighting the gasket to the block., and it would be perfectly in align, then cut the thread and slide it out. Next I would have installed heat treated brass nuts so that the next time you won't have to use the torch to remove it if there is a next time. Hope this helps someone out there as well. I really enjoy your videos there are excellent probably one of the best out there. and very detailed. UPDATE: I didn't have an issues of any exhaust leaks but decided to get this done as a preventive measure in view that ford has had a lot of problems with manifold studs breaking and then cracks in the manifolds. I am a firm believer of preventive maintenance. Keep in mind my truck only has 55,000 miles on it but it is an 05, fourteen years old so miles means nothing in this case. I did my 2005 F150 4x4 with the 5.4 Triton engine. I remove one nut and stud at a time then apply anti size to the threads and replaced them with stainless steel studs and nuts. Some were very difficult to remove but got them all out with only breaking one. Some just the nut came off the stud and left the stud in the block. Those studs I used a stud extractor and that did the trick to remove them. On the one that broke it got twisted on the end and only the tip broke leaving the nut still on the stud. I used a 6 point impact socket with an impact and now rounded off the corners of the nut and it still didn't come off the stud. I didn't think that was possible to round off the corners of a nut when using a 6 point socket, a first time for anything i guess it has never happen before. I then used a twelve point deep 1/4 dive impact socket with mag gas to heat the nut and deep creep. With 1/4 drive impact and extensions, heat and deep creep it finally came off, what a pistol. Then I still had the problem to remove the stud. The stud extractors I had were too big and I didn't have the clearance to get in there to the stud so I had to use a very short stud extractor to remove it, but it finally came out. After replacing all of the studs and nuts I used a rust removal spray and sprayed the exhaust manifolds. Then the next day I sprayed the exhaust manifolds with a heat resistant spray paint, hopefully that will keep it from rusting any more. Hopefully I won't have to do this again.

Great video as always, question about never seize, copper base with aluminum heads or the should I be using something else? Seems like three different metals, aluminum head, steel bolts, and copper never seize would not be compatible or my encourage more corrosion?

Really wonging it with those Chinese aftermarket manifolds !!

Just a suggestion.....if you have a pitted head and or manifold you can paint the gasket or head with regular silver colored never seize. It fills all the little pits and the liquid burns away. Works awesome on every one Ive tried......

I love work - could sit and watch it for hours --- Thank You for reminding me why I no longer work on my own vehicles. Protect your hands Eric - is your livelihood. (Something should arrive Sept 24 - that may help)

Shout out to Mrs. O!

You did a great job at doing that. I could not believe that some of those studs came out so easy. Without a torch to blow each nut on both sides you be there forever doing that job and sure if you tried to unbolt them rather than blow the nuts off that is what would have happened. I guess ford wants you to junk those trucks why there manifolds are outa site price wise. I just hate that cheap Chinese junk. 2 or 3 years later have to do it again? That is whats wrong with this country. I have never seen so much rust in my life like I did on that truck. I live in Michigan by Toledo, Ohio. Am sure its the type of salt they use there that eats them up that bad. Probably the whole truck will be eaten up by the next time they need manifolds

You are a master of taking things apart that have rusted and corroded.

Good job,it's good to see a machenic that still knows how to use a hot wrench,thank you sir,over and out.

Would you advise installing stainless steel studs and nuts, being in the rust belt of America?

i wont use those dorman manifolds anymore, servicing 25+ fords in the logging industry i do a set a month and the dorman ones just keep cracking.

oh yes! the rust is back. missed those videos

My favorite method of doing exhaust manifold stud removal is cutting stud to about 1/4inch, mig weld nut onto stud and turn. The welder makes enough heat.if stud breaks in head not to worry. The weld wont stick to aluminum. Just use multi pass wire.

Doors wide open, tshirts and dresses...this looks like a summer video.

I much rather the mechanical videos eric! P.s i got your package i shall be making a video opening it very soon! Thanks again

One of the best, if not the best, instructional video that I've ever seen on here. Thank you!

I will never, ever again complain about the rust we get here in Missouri..... Cross my heart and pinkie swear!

Tappy tap tap....