How To replace Exhaust Manifold on Ford Truck?

The procedure is similar for both ford and Lincoln Mark LT car models:-----

The procedure is mentioned for All engine models

4.2L,4.6L,5.4L,6.0L and 6.8L.

The details to Replace Exhaust Manifold is as follows:----

Removal & Installation

4.2L Engines 

Before servicing the vehicle, refer to the Precautions Section.

Remove or disconnect the following: 

Negative battery cable

For the right-hand manifold: the EGR valve-to-exhaust manifold tube

For the left-hand manifold: the oil level indicator tube bracket nut, then remove the oil level indicator tube. Remove and discard the oil level indicator tube O-ring.

Oxygen Sensor (O 2 S) electrical connector

The 2 catalytic converter-to-exhaust manifold nuts, then disconnect the Y-pipe from the left-hand exhaust manifold.

Exhaust manifold stud bolts, then remove the manifold mounting bolts

Exhaust manifold. Remove and discard the exhaust manifold gasket.

 

Fig. Tighten the left-hand exhaust manifold bolts in the order shown-4.2L engine

 

Fig. Tighten the right-hand exhaust manifold bolts in the order shown-4.2L engine

To install:

1. Install or connect the following:
   
   
   New exhaust manifold gasket onto the engine, then install the exhaust manifold. Tighten the bolts and stud bolts in the sequence shown to 15-22 ft. lbs. (20-30 Nm).

   Y-pipe to the exhaust manifold, then install and tighten the catalytic converter nuts to 25-34 ft. lbs. (34-46 Nm).

   O ₂ S connector, then lower the vehicle.

   Left-hand exhaust manifold: a new oil level indicator tube O-ring onto the tube. Insert the tube into the engine block and tighten the bracket retaining nut to 15-22 ft. lbs. (20-30 Nm).

   For the right-hand exhaust manifold: the EGR valve-to-exhaust manifold tube. Tighten the upper and lower fittings to 25-34 ft. lbs. (34-47 Nm).

   Negative battery cable

4.6L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Remove the left inner fenderwell.
4. Disconnect the Y-pipe at the manifold.
5. Disconnect the EGR tube.
6. Remove the manifold. Discard the gasket.
   
   NOTE

   Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
7. Clean the sealing surfaces with metal surface prep.
   
   NOTE

   Install a new exhaust manifold gasket.
   
   
   
   
   

   

   Fig. Left exhaust manifold torque sequence-4.6L engines
8. Position the left exhaust manifold and tighten the exhaust manifold nuts in the sequence shown.
9. To install, reverse the removal procedure.

Right Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Remove the starter.
4. Remove the right inner fenderwell.
5. Disconnect the Y-pipe at the manifold.
6. Remove the manifold. Discard the gasket.
   
   NOTE

   Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
7. Clean the sealing surfaces with metal surface prep.
   
   NOTE

   Install a new exhaust manifold gasket.
8. Position the right exhaust manifold and tighten the nuts in the sequence shown.
   
   
   

   

   Fig. Right exhaust manifold torque sequence-4.6L engine
9. To install, reverse the removal procedure.

5.4L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Remove the front and rear oxygen sensors.
4. Disconnect the exhaust pipes from the catalytic converters and the crossmember brackets.
5. Remove the manifold. Discard the gasket.
   
   NOTE

   Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
6. Clean the sealing surfaces with metal surface prep.
7. Install the manifold with a new gasket.
8. Tighten the exhaust manifold nuts in the sequence shown.

To install:

1. Installation is the reverse of the removal procedure. Note the following:
2. Tighten the manifold bolts, in the sequence shown, to 18 ft. lbs. (25 Nm).
3. Tighten the exhaust pipe bracket bolts to 18 ft. lbs. (25 Nm).
4. Tighten the exhaust pipe-to-converter nuts to 30 ft. lbs. (40 Nm).
   
   
   

   

   Fig. Right side exhaust manifold nut tightening sequence-2005 4.6L engine

Right Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Remove the starter.
4. Remove the right side inner fender well.
5. Disconnect the exhaust pipes at the manifolds and catalytic converters.
6. If equipped, remove the mounting bolts and position the sway bar aside.
7. Remove the manifold. Discard the gasket.
   
   NOTE

   Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
8. Clean the sealing surfaces with metal surface prep.
9. Tighten the right exhaust manifold nuts in the sequence shown.

To install:

1. Installation is the reverse of the removal procedure. Note the following:
2. Tighten the manifold bolts, in the sequence shown, to 18 ft. lbs. (25 Nm).
3. If removed, install the sway bar nuts to 22 ft. lbs. (30 Nm).
4. Tighten the exhaust pipe flange and converter nuts to 30 ft. lbs. (40 Nm).
   
   
   

   

   Fig. Right side exhaust manifold nut tightening sequence-2005 4.6L engine

6.0L Diesel Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Prior to removing the exhaust manifold, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and the cylinder head.
4. Record the measurement and compare with the specifications.
5. Remove the 2 LH exhaust manifold-to-turbocharger adapter pipe nuts.
6. Disconnect the exhaust pressure (EP) sensor tube from the LH exhaust manifold.
7. Remove the 8 bolts, 8 spacers and the LH exhaust manifold.
   
   
   

   

   Fig. Left exhaust manifold torque sequence-6.0L Diesel Engine

To install:

NOTE

Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts. When installing the exhaust manifolds, only use prevailing torque hex flange bolts with an interference fit.

1. Apply anti-seize lubricant to the bolt threads prior to installing the bolts.
2. Install the LH exhaust manifold and tighten the 8 bolts in the sequence shown. Tighten to 28 ft. lbs. (38 Nm).
3. Install the 2 LH exhaust manifold-to-turbocharger adapter pipe nuts. Tighten to 20 ft. lbs. (27 Nm).
4. Connect the EP sensor tube to the exhaust manifold. Tighten to 22 ft. lbs. (30 Nm).
5. Connect the LH and RH battery ground cables.

Right Side

1. Position the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the LH and RH battery ground cables.

Vehicles with automatic transmission

1. Remove the transmission fluid indicator. Remove the retaining nut and position the transmission fluid tube off the stud.
2. Separate the transmission fluid tube and position aside.

All vehicles

1. Prior to removing the exhaust manifold, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and the cylinder head. Record the measurement and compare with the specifications.
2. Remove the 2 RH exhaust manifold-to-turbocharger adapter pipe nuts.
3. Remove the 8 bolts and the RH exhaust manifold.

To install:

All vehicles

NOTE

Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts. When installing the exhaust manifolds, only use prevailing torque hex flange bolts with an interference fit.

1. Apply anti-seize lubricant to the bolt threads prior to installing the bolts.
2. Install the RH exhaust manifold and tighten the 8 bolts in the sequence shown. Tighten to 28 ft. lbs. (38 Nm).
3. Install the 2 RH exhaust manifold-to-turbocharger adapter pipe nuts. Tighten to 20 ft. lbs. (27 Nm).

Vehicles with automatic transmission

1. Position back and install the transmission fluid tube.
2. Position the transmission fluid tube on the stud and install the retaining nut. Install the transmission fluid indicator.

All vehicles

1. Connect the LH and RH battery ground cables.
   
   
   

   

   Fig. Right exhaust manifold torque sequence-6.0L Diesel Engine

6.8L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle.
3. Remove the air cleaner housing.
4. Remove the 2 bolts and position the degas bottle (coolant reservoir) aside.
5. Disconnect and position the brake tube retainer aside.
6. Remove the 4 exhaust manifold-to-catalytic converter nuts.
7. Remove the 10 nuts and the exhaust manifold.
   
   WARNING

   Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
   
   
   
   NOTE

   Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
8. Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
   
   
   

   

   Fig. Left side exhaust manifold torque sequence-6.8L engine
9. To install, reverse the removal procedure.
10. Torque the manifold nuts to 18 ft. lbs. (25 Nm).
11. Torque the exhaust pipe-to-manifold nuts to 30 ft. lbs. (40 Nm).

Right Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle.
3. If equipped, remove the transmission filler tube.
4. Remove the starter.
5. Remove the right inner fenderwell.
6. Remove the 4 exhaust manifold-to-catalytic converter nuts.
7. Remove the 10 nuts and the exhaust manifold.
   
   WARNING

   Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
   
   
   
   NOTE

   Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
8. Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
   
   
   

   

   Fig. Right side exhaust manifold torque sequence-6.8L engine
9. To install, reverse the removal procedure. Torque the manifold nuts to 18 ft. lbs. (25 Nm). Torque the exhaust pipe-to-manifold nuts to 30 ft. lbs. (40 Nm).

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html