broken bolt in exhaust manifold

While these can be a real bugger, I can't believe a professional tech would
let a scrubby little chunk of bolt win (though extracting things like this
can approach an art form). Since these heads are aluminum, I hope they
haven't left a real mess in their wakes....

They "usually" break with a bit of stud sticking out from the head... with
these, the easiest course is to weld a nut to the prtusion, allow everything
to cool (we must be able to touch it with bare hands) and the nub generally
comes out quite easy. If the previous attempts have left something unusable,
It will have to be cut flush and drilled out.... The drill must be centered
in the studand it must be drilled all the way through to avoid further
complications.

If they have already tried drilling it and botched that up, I'd need to see
it but there may be a head gasket in someones future if this is the case. It
would be much easier to remove the head and install a helicoil or
thread-sert in a case like this.

FWIW, these do break of on occasion... they appear to start breaking at the
rear of the manifold and can progress until several are broken. If I find
one broken stud, all the studs on that side get changed...

HTH.

<jimb6942 RemoveThis @yahoo.com> wrote in message
news:1133492764.684608.109050@g49g2000cwa.googlegroups.com...
> I have an exhust leak due to a broken bolt in the exhaust manifold in
> my 2002 expedition (5.4). I've taken it to two garages and both places
> could not get it out. Does anyone have any advice?
>
 >> Stay informed about: broken bolt in exhaust manifold 

This is unfortunately a common problem for 5.4L engines. Persoanlly I'd
raise hell with the dealer for a 3 year old truck. They might cut you a
brake. THere is a TSB related to this problem. Partial text follows:

Exhaust System - Exhaust Manifold Studs Broken

TSB 05-5-4

03/21/05

USE OF STAINLESS STEEL EXHAUST STUDS IN
SERVICE FOR 5.4L 2V ENGINE

FORD:
1997-2004 Expedition, F-150
1999-2004 F-Super Duty
1999-2005 E-Series

LINCOLN:
1998-1999 Navigator

ISSUE
Some vehicles equipped with the 5.4L 2-valve (non supercharged) engine,
may exhibit broken exhaust manifold studs.

ACTION
On the affected bank only, replace the exhaust manifold, manifold
gasket(s), and install all new stainless steel exhaust manifold studs
and nuts. Torque the studs in the cylinder head to 71-115 lb-in (8-13
N.m). Torque nuts on studs to 204-239 lb-in (23-27 N.m). Refer to
Workshop Manual Section 313-01A for exhaust manifold removal and
installation.

Ed
 >> Stay informed about: broken bolt in exhaust manifold