Ford F250 6.8 Broken Manifold Studs - Part 2

Ahhhh more rust! Gotta love it! Come along with me in this video as I finish replacing the rusted out manifold studs in this 2004 Ford F-250 with a V-10 Engine.
Miss Part I?: • Ford F250 6.8 Broken M...
What do you do if you can't drill them out!? Look here to start: • Removing Broken Exhaus...
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--Eric O.
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Disclaimer:
Due to factors beyond the control of South Main Auto Repair, it cannot guarantee against unauthorized modifications of this information, or improper use of this information. South Main Auto Repair assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. South Main Auto Repair recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video. Due to factors beyond the control of South Main Auto Repair, no information contained in this video shall create any express or implied warranty or guarantee of any particular result. Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not South Main Auto Repair.

[@jamesstaley6008]

Left hand drill bits have worked wonders for me in the past. A few that were loose came out with the drill bit alone

[@scottleclair131]

Yes they do work very good.

[@mikes4408]

You ARE the man! Great job. Can't believe there is no stud or nut or chemical that will survive more than 6 years of rust.

[@upnorth5465]

It takes just as much time cleaning never sieze off of everything as it does doing the job. That stuff is no joke.

[@baxrok2.]

Outstanding camera work on this one Eric. Although I'll never have to do this job, it's a total pleasure to watch you work, hear you explain things, and enjoy your total mastery of all things mechanical.

[@jeffmeng4479]

A pleasure and privilege to watch Eric O. Work

[@SushiPac]

Holy moly that under side of that truck is CRUSTY!!!!!!. I think that leaking manifold is the least of that customers worries. Better off just purchasing a new truck I think

[@stihlhead3338]

Man, I wish I had half your patience. Love watching your videos. Nice to be able to watch a video without all the f-bombs.

[@bchrisl1491]

Masterfully done. Take a piece of stud and bevel the end slightly and drill a pilot hole exactly through the center hold it with channel locks and start your drill in the stud.

[@grizzlydan8]

+BChrisL * Great tip. sounds like it would work. Thanks.

[@bonsaiking405]

BChrisL what exactly do you mean? I'm doing the same job to my Excursion and I am having issues with 3 studs that are out but seized up and 3 that are broken in about the same on the video

[@AntonioClaudioMichael]

Caught 99 percent of job on camera was very helpful I'm fortunate to have a v10 in a state that has no snow but I'm doing a complete engine rebuild

[@hawaiianf1504]

Awesome Video! Good thing you had the prior work order and used anti-seize on those studs. I've had my share of drilling out busted, rusted and dusted studs. Absolutely at the mercy of the last mechanic to touch them. I had to keep a fair share of disposable jobber length drill bits especially in small sizes for the pilot holes. Usually got them in 10 packs. Broken tap or drill bits are a serious pain. Centering it the first time is critical following the angle before you get 1/32" in. Bad angle equal bad day.

[@4SaleBrunswick210]

Excellent instructional video! I now have the confidence to tackle the broken studs on my 2005 F-350 V-10. God help me!

[@anhnambinhtrungtay7330]

A job worth doing it twice! I must hand it to you Mr O, as you got some quality skills of get those broken bolts out. Well done!

[@PeteyG708]

"Its easy... and its out." Haha! Those things are pretty cool and handy. Tell Mrs. O that I hope she feels better! Being sick sucks! Don't get sick yourself, sir!

[@SouthMainAuto]

+Pete Gaytan III She is getting better but the bug hung a round for a while...

[@montehyler]

Good video. Broken off bolts and studs, especially in places that are hard to reach, are the bane of all of us DIY'ers! Keep up the good work!

[@SouthMainAuto]

+Monte Hyler we all have to start somewhere

[@MemphisApplegate]

"If it don't fit, force it." The part everyone hates about working on cars is not having easy access to whatever you're working on. And I think this problem is getting worse on the newer cars. As always, good job. Man, that rust-belt is sure hard on cars!!! The underside of that Ford looked like it was a hundred years old.

[@SouthMainAuto]

+Memphis Applegate It was a mess huh!? Maybe I can send it over and you can do a Memphis Monday special on it ;)

[@rudyossanchez]

I'm always bitching about the heat down here in Miami, when I'm working in my car. but after seeing all that rust, I'm going to keep my mouth shut.

[@SouthMainAuto]

+rudyossanchez Haha It is a love hate I have with the rust

[@crisprtalk6963]

Its a good thing SMA on KZbin wasn't around when I was in college.

[@mawolff23]

This one time I was at the dinner table and was asked what I was thankful for. I told them I was thankful for all the hard work that Eric O puts into his videos which allows me to feel as if I can go out and do the job myself. Great work Eric, Keep it up.

[@SouthMainAuto]

+WRX Mike Lol thanks Mike!

[@63256325N]

Personally I'd have gone straight for the left handed twist drills for that one. They work wonders on stuff like this. I hear you with the never seize, just looking at it does'it for me. Great job on the repair. Thanks for the video.

[@petemoss9693]

One hell of a ass kicking job - . . . now it's Happy Hour Time ! Get well Mrs . O

[@andreaechevarria6725]

Words to live by. If you're gonna drill, drill straight! Enjoyed the video. You've gotten really good at it. Made a boring job interesting. Thanks.

[@skynetlabs]

His invoice is going to be more than that rust-bucket V10 is worth!

[@plumbdog845]

I usually weld a nut to the end of the broken stud and then pull it out. It also works when the stud is below the face of the head. Add some weld on the end of the stud to get it flush with the head, clean it up and weld a nut on. Always had good luck. Heads are aluminum and studs are steel

[@paulmelah8667]

sucked cause Mrs. O was sick and Trinity would not say hi lol hope Mrs. O is feeling better by now keep up the good work and the videos...... waiting for the next one

[@nunyabiz8887]

I know this is way late, but hoping you got to feeling better real quick Mrs. O.

[@frankmuhammad9660]

I am glad those last two did not give u too bad a time. I was hanging on the edge of my seat like a horror movie!!!!!

[@GeraldThomasphotojunkie]

Great show! My turn this weekend on my 93 Jeep 4 banger. I've put it off for about a year and a half, and I have 0 excuses being a mechanic myself. Thanks for the inspiration. ;-)

[@SouthMainAuto]

Go get it man!

[@michaelstjohn6086]

why do we despise working on our own stuff?!

[@kenj.8897]

​@@michaelstjohn6086shoe cobblers kids have no shoes

[@michaelstjohn6086]

@@kenj.8897 and never go in a carpenters house.

[@rbarr1200]

Your videos are gold.

[@SouthMainAuto]

+Ricardo Barron I wish!

[@michaelinlv]

Where I grew up (Rural NC). the siren was a noon everyday. It was the fire department volunteer call. If it blasted more than one at 1200 it was a fire department call that happened at 1200.

[@skokie23]

Eric I thank you on taking the time to video all of this for us to watch and I cant speak for anyone else but I have learned from them so please keep those vids coming!

[@SouthMainAuto]

+skokie23 Thanks

[@vindictives1]

I have done pass side on mine and a friends truck and I find if you take the shock and the mount out you get a ton more room but love your vids and I'm a new sub👍👍👍

[@davidpond6883]

You made that look easy. I have a V10 in my shop now with seven broken studs on the left hand manifold. None of the are moving at all. I removed the shock and shock tower for more room. Going to try 90 degree angle drill to get around the steering shaft. I have also seen people weld a nut to the studs to try to get them out. I guess if they never come out there is a point where you just throw in the towel and remove the head?

[@samueljames9342]

Get you a set of left twistbits, they work great on the studs that aren't locked up.

[@Fuddpucker2009]

Fantastic video. Love the description on what is being done as well as you never seem to get wound up. Nice to have lunch ready by Mrs O and have the family at work.

[@wyattoneable]

This is my new morning car show. More informative, no commercials and always entertaining. I hope Mrs. O feels better soon.

[@SouthMainAuto]

+wyattoneable Hey Wyatt glad to hear that thanks!

[@CHIBA280CRV]

Wow ! That was harder than rebuilding the heads on the Subaru !..and the name we were looking for was Mac tool for 200.. It was on the handle, come on Eric..lol...thanks for another fine video , and hope the wife feels much better....now get back to work...

[@mgb961]

I imagined you were Luke Skywalker with that music....aiming to hit centre of the death star...and BOOM...hit the target...bolt cae out....great vid

[@stevebrooks5744]

Hey Eric, thanks for all the great videos! I really enjoy watching and getting the feel for a repair that I have never done before, before I try to tackle it, since I am not a mechanic by trade. My 90 degree air drill has the same reverse button, so I cut an old piece of 5/8" diameter rubber vacuum hose about a 1/4" long and notch it out to a "C" shape and insert it under the reverse button and then remove if I need to use it in reverse, which is almost never. Keep up with the great videos! Tim Nyp in Columbus, OH

[@johndonovan5894]

A pleasure to watch a pro, looking at a '99 RV with a Triton v-10. Rotten exhaust manifold bolts are a nagging issue with these. This convinced me that's not happening.

[@benjaminstewart1128]

You sir are a Legend! Absolutely love all of your videos, they are made with excellence and quality. I hope your business continues to thrive!

[@douglasthompson2740]

Hello Eric, I have often had good luck with a left handed drill bit. If you get lucky it will spin the broken off threads right out. Easy outs are like a prayer to the gods on a windy day! Take care. Doug

[@phillipmccormick1508]

WOW, you are the man ya, Eric I like to see you do a thing like that, I am a little too old to do that but ya, you are the man.

[@jackgreen412]

My 04 Ranger started life in Oil City, then lived 8 yrs. in Jamestown, commuting to Dunkirk, now residing in Tennessee. Underside much like that. It''ll run till it drops-breaks.

[@mopardave4935]

I broke the bolt off in the manifold on a 4.7 Dakota. drilled it out, broke the drill bit. Got something called a " Rescue bit " and that worked really well to disintegrate the bit. Ran the tap in there to get some threads and yupppp broke that off too.... Apparently when i had the tap in my pocket the whole time drilling the bit out it made it weaker or something and that's what did it... Tungsten steel bits worked very well with the broken tap just an FYI. I had alot of fun on that job, got screwed 10x sideways hahaha. But i laugh and learn from that mistake now! Great video Eric.

[@SouthMainAuto]

+Mopar Dave Wow dude that is crazy!

[@huggybryn39]

Well done on reaching 18000 subscribers and still growing, best auto mechanic and tech. on utube. Hope the Mrs is feeling a lot better

[@williammiller9499]

Just want to thank you for your CV axle GM video that helped me change mine on a '94 K1500 that was from rust country. Great videos that have lots of helpful info on dealing with rust belt vehicles.

[@anomamos9095]

Watching your videos reminds me of the time I was stupid enough to work as a mechanic for a living. I was cured of this idiocy by the head on a V12 Xjs Jag. I was removing it had it all undone and ready to come off , they are a light alloy head so I started to lift it off unassisted when it stopped moving due to corrosion that had built up around the stud holes and caught on the threads as I lifted. Pop went one of the disks in my back. Now I work on computers. Working on computer systems I seem to have fewer visits from Murphy. My favourite Murphy visits were, struggling to thread a manifold or some other awkward part into place where you have to leaver stuff out of the way and contort and scrape off flesh you get it on reach for the nut or bolt to do it up and it falls straight onto the ground like there was absolutely nothing in it's way, but no way can you get to go on again without struggling again. As for drilling out broken studs almost every third time no matter how centred I had the drill even if it was held in a vise and I used a drill press it would scew off to the side and either shape the drill or the tap.

[@Blackford86]

Good job, it always help when you got a garage and a lift, better than crawling around on you back enjoyed the video

[@wysetech2000]

Well done, Eric for such a PITA job. It pays to take your time and have good tools and sharp drill bits. The last one I did was a E Series, right side on a 95f day. I replaced the manifold with a Dorman that had a pin hole in it and had the privilege of doing it a second time. BLahhh!

[@SouthMainAuto]

+wysetech2000 Damn! I'm sorry....

[@wysetech2000]

+South Main Auto Repair Thank you for your sympathy.....LoL.

[@M_Hiser]

wish I lived closer to you, my Ex needs this on the drivers side too

[@jefferypowell9885]

Bolts come out good video

[@smokeskull]

i am going to have to send you a bill for my time as a shop foreman for watching you do that job. i just did a bunch of broken studs on a hino truck and they were hard like diamonds. i had a 3 foot pry bar levering against my drill just to get through them.

[@SouthMainAuto]

+smoke skull Haha I hope your labor rate isn't to bad. If I encounter a hard one I use a masonry bit that I sharpened. Gets right through them :)

[@smokeskull]

You should know how much us auto techs work for free. I actually watched it while having lunch so this ones a freebee. Hmmm is that a freemasons secret, never heard of that one before.

[@SouthMainAuto]

When I use to worked as a gun smith the master I worked with showed me that trick ;)

[@chrisfreemesser5707]

No wonder Ford trucks are the best selling vehicle in the US...you have to replace them every few years when the frame rots out. ;) Another interesting and informative video...thanks Eric!

[@Discretesignals]

One of the things I learned from Keith Fenner was that an EZ out is a misnomer. They work great for what you used it for, Eric, because the broken off studs' threads were not all cross-threaded or galled up and you saw some rotation. If someone broke a bolt or stud off getting it out because someone else had crossed it (new threads are better than old), an EZ out isn't going to help and make matters worse when it breaks off.

[@christopherpike3073]

Nice work !! Thanks for sharing

[@MaicSalazarDiagnostics]

Great video Erick! Hope your wife is better now! You have a wonderful family! Happy thanksgiving!

[@xorfive]

You are a kick ass mechanic!

[@billrimmer5596]

Thank u Eric!! For years in American V-8 gasket sets., u would always find these sandwiched perforated exhaust manifold gaskets that if u used them, u would end up with a noisy or cracked manifold within a few months. On Chevys, no gasket, on Pontiacs the factory type steel shim gasket seemed to work better. The gaskets that u took off seemed like the old junky ones that I am talking about. I wonder what the OEM's look like. Thanks Eric. Video turned out perfect. In part one loved the fast forward and music on the fender liner.

[@markwheeler202]

You fired up that drill and everyone 1) yanked their headphones off and 2) yelled "Hearing protection!", 'cause that's what Mrs. O. would say. :-)

[@denniswilkinson1118]

Great video. Once again patience prevails. You make that type of work look like magic. I've had good luck with a left hand drill also as you mentioned, but then my job was clamped to a milling machine table.

[@JohnRodriguesPhotographer]

God bless the inventor of Easy Outs and stripped nut removers!

[@mph5896]

Nice, looks like they came out nice and easy. Factory bolts use loctite on them instead of never seize.

[@robertdavis6708]

I put a Gale Banks stainless header kit on my 2001 F-450 motorhome. It took me two hard days getting to the header bolts, but I didn't remove the inner panels. After seeing your vid., I wish I had. Man have you got patience!

[@raybrensike42]

I grew up in MN, and we had rusty cars but not that bad. We had holes in the floors and under the doors, and I even had a friend who had a leaf spring in the trunk, and I thought it was an extra leaf spring he had, but no. It was just the leaf spring....in the trunk.

[@mechtechtools838]

You are really good at removing broken studs. I don't think your viewers realize how tough it can be. I guess you get lots of practice working on rusty trucks all the time

[@SouthMainAuto]

+buzzerauto I have done it a time or 2 :)

[@garysgarage3669]

Thank you for taking the time to make this and all your videos. I have learned a lot of tricks from you. I even think I'm going to tackle my front diff. on my truck. Was a little nerves about removing the rusty cross member bolts. Hope your wife is feeling better.

[@ericstoneberger4504]

I praise you for always doing your best work no matter the condition of the vehicle. I know I would struggle even wanting to attempt this job, seeing how rotted/rusted she is. all and all great job and great content. keep up the good work!

[@geoffrundlett1697]

Bad news is I learned my truck has a DNA problem (made wrong). Good news is I learned it from Eric O., so I know how to cope with it. Thanks for the coverage; liked the video for sure! Any recommendation on whose (or what material) replacement studs / nuts / hardware should be used would be appreciated. i.e. I'm not sure "stainless" is the way to go here. I see people offering "coated". Don't know who to trust (except Eric).

[@TitanFallDeath666420]

Lol That Star Wars Music almost made me fall out my chair laughing.... Nice Job Dr O...

[@gunlover1955]

The heat is some good information I have found that heating the stud just to red and not the head so much is best and when it is cooling off put some ice on the head just above the stud it works for me. I just put the ice in a rag and hold it up there for a minute it cools the head and breaks the bond from the stud. Great job by the way I hope this helps the next guy out. OH and this may sound dumb but that last one take a 7/16" drill bit and drill out the first 2 or 3 treads in the head then they turn right out most of the time I used to do this 35 years ago on diesel trucks. I did not have KZbin when I was young you are a good mechanic. Keep the information flowing!

[@AntonioClaudioMichael]

Great video

[@deepsquat600]

on your whistle.... When I was a kid in Tacoma WA there was a siren everyday at 2 ..went off in several places ..apparently left over practice from WW2 ..( never needed obviously ) they stopped it about 20 years ago .. Now we have them in the Shadow of Mt Rainier ..if that baby blows off you have about 20 minutes to hit high ground ( good luck you should see the traffic jams they get without a siren) and the Wa coast has Tsunami sirens in case California slides into the ocean :)

[@SouthMainAuto]

+deepsquat600 Oh wow, I'd just be loafing around thinking it was lunch time haha

[@yatesyification]

I've switched from Eric The Car Guy to you!! Your much more professional.

[@SteveRobReviews]

+ Ben This is Eric the car guy , ok today Eric the truck guy :) either way a top notch Premium Tech , I lick em.

[@SouthMainAuto]

+Steve Rob please, please I ask that you do not lick me....

[@SteveRobReviews]

+Eric haha , oops -------:)

[@RealCadde]

+South Main Auto Repair **SLOBBER SLOBBER**

[@chungaleta1234]

+Ben Yates Same over here. Lengthy videos and actual repairs on each of them.

[@rosscampbell6644]

hi eric when your stuck for a dienut cut a slot though one flat of the spare nut you may have the slot gives an out for crud and can expand a little in ya socket while going back and forward ..theres a lot of luck needed with the easy out...great vid as allways

[@DaveSender66]

Another job well done! Bring the next victim in the OR . Good work Dr. O !!!!!

[@SouthMainAuto]

+DaveSender66 I am sure there will be more :)

[@michaelwears4262]

A little trick I learned once upon a time on the individual gasket that fall off before ya can get the manifold up in place was to bend the end stud hole just a little enough to hold gasket in place. Very good video, my exhaust man says how hard it is to change manifolds on 4.6. You make it look easy!!

[@Tem782]

Rust attack! Nice to see good working space. A NIGHTMARE job if you cant fit your hand between body and engine....Keep videos coming...!!

[@kittty2005]

I had the same junk that Mrs.O's got,got over it quick she will too,I bet.

[@unamusedarchitect1646]

I am so glad I found your videos. I’m starting in the Uhaul mechanic dep in two weeks. And they have to extract manifold studs at least 3 times a week.

[@MarkFox]

Another great video production here and Eric O sure seems to be able to keep his cool when I would be swearing like my US Navy days. If I lived close to this shop Eric would definitely be my mechanic instead of me doing it myself swearing profusely for the enjoyment of my neighbors. The sad thing is I work on motorcycles but hate doing any kind of work on my own car.

[@retiredchief7469]

I am not looking forward to fixing the exhaust leak and missing rear stud, drivers side of my 2009 6.8 F350. Thanks for the helpful tips Mr O.

[@JeffreyStrader]

Your videos are always THUMBS UP and well appreciated Eric.

[@Notsodirt]

great video. so glad we don't use salt where i live.... so many things would be dead from crusty rusty.

[@dustinsigmon1342]

Had an interesting circumstance the other day changing the passenger side manifold on an 05 F150. Finished with the manifold, had the batter disconnected since I didn't remove the starter. Finished buttoning up the exhaust and connected the battery, started the truck to see that it was in Engine Failsafe Mode. Checked my codes P2104 & P2111. 2104 is a status code (failsafe mode) and 2111 is throttle control unit stuck closed. Removed the air box to inspect the throttle body to find that the actuator motor was still functioning, and moving in coordination with the accelerator pedal (slow 0-100%). Long story short replaced the throttle body to get the fault to clear and stay gone. Tried replacing just the actuator motor and that didn't fix the problem. Upon visual inspection the throttle stop screw had been tampered with and broke so that there was no longer a functional spring loaded plunger in the stop screw. My believe is that disconnecting the battery overnight cleared the ECU memory of throttle tables. That screw/ bolt with that spring inside of it stops some type of throttle plate movement that the ECU doesn't like and causes it to think that the plate is stuck. When I tested the TPS it was correct on both the high and low sensor outputs.Maybe you heard of or saw something like this before. I thought you might find it interesting.

[@rauver6726]

You make it look easy

[@stevenpdxedu]

That much scaly rust at only 30,000 miles . . . what the heck do they put on the roads there Ospho? Thanks for the video I learned a bunch.

[@farmboy30117]

...and Eric O. said Rust just come on back if you ever want to play again, 'cause I told you once you SOB, I'm the best there's ever been!

[@SouthMainAuto]

+farmboy30117 Haha Think we could get Charlie to do the remix?

[@farmboy30117]

Heck, I just hope he don't sue ;)

[@andreblanchard9786]

Outstanding vid Eric once again!!! Always enjoy watching your vids, don’t worry about out of focus camera - we still get the message!!! Great help for a wannabe mechanic lol. Thanks again!

[@dhynes5380]

I have a '97 Econoline 6.8 Super Cube....not looking forward to this. At least rust will not be an issue for mine! Great video - thanks for the info

[@douglasthompson2740]

P.S. A set of collars made with an assortment od's inserted into the hole would help keep your center punch and drill bits lined up as you start. Something anyone with a lathe could knock out quickly and it wouldn't take many to cover your sizes. Doug

[@kenman1717]

hmmm, 6 year old never seize. I can see that. still surprised you didn't need to pull out the welder. great video.

[@OOZ662]

We have the occasional 12:01 alarm here, though it's just the refinery testing their alarms. Aww, poor Mrs. I don't have sacks of money to send, but hope she feels better soon.

[@charlesmiller5078]

Makes me think I can tackle my busted bolt on my Z, Only problem is both the intake and Exhaust are both on the same side, But at least the bolt looks to be sticking out maybe 1/2 inch or so. These intakes have so much crap on them, anyway I look at it , going to be a pain, Guess I will replace all the studs while I have it apart. Right now working on Replacing my hood on the Z, and repainting it, Putting in a slight slope in my "back Yard" to help drain water away from my shop, also installing a new power wire to my back shop 300 foot behind my main shop, So 3 or 4 things going at once. You are really talented at what you do, its fun to watch, and try to guess what your going to do next. Stay warm, Hope Vanessa starts feeling better soon.

[@SouthMainAuto]

+Charles Miller Hey Charles I though you were retired and napped all day!? Boy I was wrong. After reading about the work you have to do just so you can do more work is making me tired!

[@charlesmiller5078]

Well when I was still working I just put off so many things that needed to be done around here, And Im not all out retired yet My old Company still call me in every couple of months to train a new drivers on unloading these deadly products that we carry. Nice thing is I usually get the newest Truck on the yard, and it normally takes around 4 weeks to finish training a new guy, at least its all local, and I only drive 50% of the time. They want to put me into a dispatcher position, but 5 days a week not what I want to do right now, Just have to much to do. As much as I do around here the list just keeps getting longer. But I enjoy getting things done. Whats cool about your job is you dont know whats next to come through the door, and you keep real busy, which keeps you out of trouble. :)

[@markp4967]

I cannot imagine the bill for that job! Great work👍🏻

[@ericcorse]

Never seize will save your bacon. Well done and I hope your wife is feeling better by now.

[@headylynn]

your videos are really good,I have learned a lot..I enjoy when you have your family on them also..

[@702havingfun]

thanks for the video i extracted 2 studs with the weld nut method it didnt work until i started praying then it came right out true story!thanks!

[@risc19]

One two barbeque baby!

[@whatdoyouthinktodd]

Take good care of Mrs O.

[@SouthMainAuto]

+bub dog I try.....

[@xXFirstHandGamerMatt]

Buddy at 16:58 in the background making sure that bolt never comes out

[@VWWRENCHIE]

Pain in the studs man..helluva job!👍