Ford 7.3L Power Stroke (1999-2003) :: Exhaust Leak At Passenger Side Up-pipe To Manifold - P1211 And P1280
I just finished installing a new turbo (shaft play and lots of oil in the compressor side), RR up-pipes, and T500 (250k and once had a very long crank to get the ICP up to start).
Anyway, except for another exhaust leak at the pass side up-pipe to manifold, it seemed to run okay but with lots of white smoke. I only have about 50 miles after the install, when it suddenly starting surging and made a lot of loud knocking noises. This then went away and came back again rather quickly. I was close to home, so I made back under power. I also received the two codes listed. My IPR is original, but two summers ago I installed the IPR re-seal kit. Everything on the IPR looked good when it came off for the T500.
After reading around, I saw that low fuel pressure / air in fuel can cause problems. I connected a pressure gauge to the pre-filter port on the filter housing, and got 40psi at idle. I then took a diesel shower and blew out the fuel line into the tank. After re-connecting it, the fuel pressure stayed the same but the engines idles much better, but still has blue smoke. It's the original fuel pump (to me anyway) and original fuel line connections.
I have about 3/4 tank, and no place to put it, so I'd need to run it out for the Hutch mod, or least to get in there and inspect. Would eliminating the Ford connections at the pump be worthwhile for now, and is 40psi at idle adequate? Wondering if it's time for a fuel pump?
Ford 7.3L Power Stroke (1999-2003) :: Exhaust Manifold Bolts Broken?
Just bought a 03, the seller showed me a exhaust leak. I found a bolt broken off, flush with the head. Looked at the passenger side when I got home, that side leaks too, and found one broken off bolt there too. Question, are these easy to do? As in, I have extracted broken bolts before, but they where on my V10 and I could just weld nuts to them and they came right out.
View 14 RepliesFord 7.3L Power Stroke (1999-2003) :: Broken Exhaust Manifold Bolt
So I received my International bellowed up pipes from Riffraff and I figure I will start soaking all of the bolts with some aerokroil before I get started on monday and I see the very last bolt head near the up pipe is gone. The bolt is there but the head is gone and you can definitely see soot buildup everywhere near it. I don't know if I should order a new manifold for the passenger side and new bolts, order a driver and passenger side manifold and new bolts, or just order one set of new bolts and try to get take the passenger side manifold off and replace the one broken bolt.
View 4 RepliesFord 7.3L Power Stroke (1999-2003) :: Exhaust Manifold Removal - 1 Bolt Stuck?
I managed to get the drivers side exhaust manifold and all of its bolts off no problem. On the passenger side I had 1 bolt head that was already broken and I have only 1 other that is still holding on for dear life. I've been soaking it in aerokroil for awhile now and no luck. I tried some PB blaster today because I am willing to try anything. I also tried heating up the bolt with a torch and some map gas but not sure if I am heating it up enough or not. Anyways, everything else has been going great, got the uppipes off and the valley, turbo and pedestal all cleaned up good. Just need to get the last whole bolt and broken bolt out so I can install the new manifolds. What I should try to remove the last 2 bolts. How hot should I get the bolt when trying to remove it? Or should I be heating the engine block?
View 12 RepliesFord 7.3L Power Stroke (1999-2003) :: Broke Off Bolt In Exhaust Manifold To Head
Well i had an exhaust leak on this F250 and so I started torquing the bolts on the manifold to the head. (45 ft.lbs) A couple were very loose so I was thinking "Great, this may fix my problem!"
My first mistake was probably the Harbor Freight Tools torque wrench.
I am on the driver side, second from the rear and then bang! I see a gaping hole where the bolt used to be. Bolt on the floor. I cant see up in the hole to the head, I think it broke flush with the head.
Ford 7.3L Power Stroke (1999-2003) :: Oil Leaking From Driver Side Exhaust Manifold At Junction With Up-Pipe
I had a fuel starvation problem because Ford painted the inside of the fuel tank and the paint was coming off and clogging the filters and because I foolishly drove it I now have white smoke spewing out of the tail pipe and an engine miss.
I also explained that I thought that the white smoke did not smell sweet like antifreeze, but rather like diesel. (Hoping that a head gasket replacement is not required.)
I am in the middle of doing the Hutch Mod with frame-mounted Racor PS120-2 jar-type screen pre-pump filter and shortening my previous Harpoon Mod and paint stripping and powerwashing the inside of my tank. Next I plan to move on toward the engine issue.
This evening I was under the van with a flashlight and I noticed that there was a black liquid of some sort at the driver's side exhaust manifold where it joins the up-pipe. At first I was afraid to touch it fearing that it would be carbon-sooted water, but it felt and tasted like carbon-sooted diesel.
And since I haven't started the engine in two weeks and it has been routinely near or over 100F in Sacramento, water would have likely evaporated days ago.
Does it make sense if the fuel starvation problem caused an injector nozzle or its cup to crack or to stick open or to otherwise spew unburnt fuel into the exhaust manifold which would cause the white smoke? Obviously, the unburnt fuel must get from the affected cylinder(s) to the tail pipe somehow, which likely means out the exhaust valve, through the exhaust manifold to the up-pipe and through the turbo to the exhaust pipe and finally to the tail pipe.
See pictures at my CP. I can't figure out how to attach them or put them inline here because it still says I can't do attachments.
What is my next move? Remove the driver's side valve cover? If so, what should I look for, etc.?
2002 E350 extended body van 7.3 diesel auto trans converted to 4x4 (bought new)
Ford Super Duty (1999-2016) :: 2003 F350 V10 - Exhaust Manifold Leak?
2003 F350 short bed 6.8L V10---On start up a slight tap sound, almost like a cranky lifter, but it is an exhaust manifold leak. At the bolts, I am not sure. This has been this way for 5 years, no better no worse. After I run about 2 to 3 minutes it seals itself. Not a hint of noise. Due to heat, something is expanding to seal it (aluminum).
At my annual PA. State Safety Inspection the Tech says 'that has to be corrected if it worsens', but It does not fail inspection. This puzzles me.
How is the call made for correction. A flip of the coin, a guess and is it serious enough to fail inspection. Is this normal with the 6.8L or V10s. I know the cost involved for a fix is big league, but can it be justified. TRUCK RUNS GREAT !---
Ford 6.0L Power Stroke Diesel :: Exhaust Manifold Leak - Sounds Like Air Rushing Out From Driver Side Of Engine
So I started my truck this morning and it sounds like air rushing out from the driver side of the engine. I currently have my ICP unplugged due to a bad sensor, will be replacing it on Sat. Also I have been having an issue with my turbo but I don't think that it's related as I here the air rushing sound when at idle as well at when driving. It seems to be a bit louder when the engine is cold but I could also be crazy about that.
View 3 RepliesFord F-150 - 1997-2003 :: Exhaust Leak On Passenger Side / Broken Exhaust Manifold Bolts
My wife's 97 f150 4x4 had an exhaust leak on the passenger side. 7 out of the 8 bolts holding the manifold on are snapped off. 4 of them are snapped off 1/8" below the top of the hole on the cylinder head . I am I unable to get a drill in to drill these out. The other 3 I've tried welding a nut on these but they won't budge and I wring the nuts off. If I have to pull the head(something I don't want to do)can I just pull that 1 head or do I have to tear the intake and everything off?
View 1 RepliesFord 7.3L Power Stroke (1999-2003) :: Massive Exhaust Leak
New up pipe and manifold gasket time!
Massive exhaust leak.. Likely the reason for my 5psi boost.
Wish I had the funds for headers but on the up side, no broken bolts!
Ford 7.3L Power Stroke (1999-2003) :: Engine Ticking - Exhaust Leak?
As it says, I have a tick. It's not apparent at idle and increases with engine speed.
Just spent $570 having bellowed up-pipes installed and while a little quieter, the tick is still there. What else tends to go out on these things? Manifold(s) cracked, manifold gasket(s)? It's seen high EGT's quite a bit but not for longer than 20-25 seconds.
Ford F-150 - 1997-2003 :: Possible Manifold Leak In Exhaust
So I think I have possible manifold leak in my exhaust and its because when the engine is super cold, and I do have a straight pipe, but it sounds like a tractor... until it warms up after few minutes, it goes away.
My exhaust manifolds are rusted to crap and stuff is falling off, paint or whatever there was on them.
Now I've looked at bunch of videos on UT to get a better understanding since everyone says the nuts and studs are hard to remove or snap.
Now my question to anyone who's done this in their garage; I've seen bunch of videos where the stud snaps flush, then he takes a nut, puts it over the hole, holds it up with needle pliers and uses a MIG to start welding it... stud to nut... then puts a wrench and off it goes.
Now, I'm not a pro welder or anything so is it possible to by accident weld the stud, nut into the head and then never ever be able to undo or take either one out?? or is the head or whatever made from different material that won't get welded to the nut or the stud??
Ford Super Duty (1999-2016) :: Exhaust Manifold Leak Repair
The exhaust leak is not too horrible, but, enough that I need to address it soon. Only on the driver's side; (today).
I'm planning on having a lot of PB blaster on hand, torch, broken stud removers, screw/stud extractors (easy outs), ...a hammer. Maybe a few cold Budweisers
Ford Super Duty (1999-2016) :: Exhaust Manifold Leak Causing CEL To Blink?
I've got a 2006 F250 5.4l. Recently Ive had an issue when I am driving, usually when the engine is at 3k+ RPMs, where the engine will lose power and the cel with blink. Usually it only takes a few seconds for the blinking to stop and the engine continues as normal. Now, I know that at least one of my exhaust manifolds are leaking.
Could it be that the engine is not receiving enough back pressure and that is causing it to lose power? I had a similar issue last year, basically the same symptoms, and it turned out that I had two cylinders misfiring. I replaced the coil packs and that fixed it. This time there are no codes referring to a cylinder misfire. There is a code for EVAP leak (I think), but I was told it was nothing to worry about.
Ford Super Duty (1999-2016) :: 2008 F250 - Exhaust Manifold Leak
is there a set of headers for my 2008 f250 5.4 rwd that will install somewhat easily without me throwing tools across the garage? I see a lot more options for the older trucks. I have a pretty annoying exhaust manifold leak and I figure I might as well throw some headers on if im gonna be in there. I really want to go for sound rather than power. I think I saw a set by flowmaster that looked decent.
View 6 RepliesFord Super Duty (1999-2016) :: F250 - Exhaust Manifold Leak On Passenger Side
Should I attempt to replace the passenger side manifold with what I can get from Napa. I would rather pay 100 bucks for everything and do it myself. But, Im concerned about replacing the studs. From what I have read the studs seam to be the problems for most leaks on these vehicles. I have torque equip. and other tools to do the job. Just want others opinions about this project. How hard really is it? 1999 5.4L F250 SDuty....
View 14 RepliesFord Super Duty (1999-2016) :: Rough Idle - Exhaust Leak Between Manifold And Turbo
I have an exhaust leak between the manifold and turbo ( in the flex part of the pipe) on my 2008 6.4 f250 would this create rough idle when at operating temp?
View 2 RepliesFord Exhaust :: Exhaust Manifold Leak Due To Broken Rusted Bolts
I have a 97 Expedition with the 5.4 engine and 160k miles. Recently while having other work done I was told that I had an exhaust manifold leak due to broken rusted bolts.
View 3 RepliesFord Exhaust System :: Exhaust Leak At Manifold Where Donut Gasket Meets The Catalytic Converters
My truck just started running really loud when it's cold and the leak goes away when it warms up to operating temperature.I did a little bit of investigating and I have found where the leak is coming from at the end of the exhaust manifold where the donut gasket meets the catalytic converters. It appears that the bolts rotted that hold the system together at the gasket. What should I do to repair this? I don't really want to replace the whole manifold because I know I'll break a stud off in the engine because everything is pretty rusty down there. I even took some pictures of the problem....
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