Exhaust System - Broken Exhaust Manifold Studs

TSB 09-22-8

11/16/09

STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L
2V ENGINES

FORD:
1997-2004 Expedition, F-150
1999-2010 E-Series, F-Super Duty
2000-2005 Excursion

LINCOLN:
1998-1999 Navigator

This article supersedes TSB 5-5-4 to update the vehicle model years and engine application.

ISSUE
Some 1997-2010 F-Series, 1999-2010 E-Series, 2000-2005 Excursion, 1997-2004 Expedition and 1998-1999 Navigators equipped with the 5.4L or 6.8L 2-valve (non supercharged) engine, may exhibit broken exhaust manifold studs.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Refer to Workshop Manual, Section 303-01 for exhaust manifold removal and installation for the affected engine bank only.

1. Replace exhaust manifold.

2. Replace manifold gasket.

3. Install all new stainless steel exhaust manifold studs and nuts.

4. Torque the studs in the cylinder head to 71-115 lb-in (8-13 N.m).

5. Torque nuts on studs to 204-239 lb-in (23-27 N.m).





Parts Block

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION DESCRIPTION TIME

MT092208 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor
Performed As Actual Time

DEALER CODING
CONDITION
BASIC PART NO. CODE
9430 24





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