exhaust manifolds leaking - Ford Powerstroke Diesel Forum

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post #1 of 16 Old 02-24-2010, 05:47 AM Thread Starter
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exhaust manifolds leaking

just before the warranty ended on my 04 F350 6.0 ended i sent it to the dealer with with a coolant loss problem they had it for a week and replaced the egr cooler and oil cooler .I also told them the manifold was leaking on the passenger side but thy didnt fix it .Now both sides leak and the cab smells like exhaust. Should this have been covered under the 5yr 100000 warranty and any ideas on how much this will cost me to have fixed now that the warranty is up ?
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post #2 of 16 Old 02-24-2010, 06:34 AM
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I think that since you told them about it, it should have been fixed under warranty. Go back to the dealer and see what they say.


1991 Volkswagen Jetta 1.6TD ECOdiesel -- 423,000 miles
2003 Ford F-350 6.0 -- 131,000 miles
1987 Mercedes-Benz 300SDL -- 307,500 miles

2000 Volkswagen New Beetle TDI (RIP)
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post #3 of 16 Old 02-24-2010, 06:48 AM
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take it tback and ttell them you had it in here under warranty to fix an manifold leak and itt still leaks. they should be able to help you out.
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post #4 of 16 Old 02-24-2010, 05:06 PM Thread Starter
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the dealer didnt even try to fix the leak that i know of. after being with out my truck for a week I was just glad to get it back I should have paid better attention to what they did. I think I would have a hard time getting them to fix it now it has been around ten months sense then.its just alot more noticable now that it smells of exhaust in the cab
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post #5 of 16 Old 02-24-2010, 05:39 PM
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best bet is to pull the manifolds off and add gaskets as our trucks did not come from the factory with exhaust manifold gaskets

Adam Brannan

First Coast Diesel Performance

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post #6 of 16 Old 02-24-2010, 05:57 PM Thread Starter
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6 yrs of snowplowing in northeast winters have taken there toal on the manifolds they are extremly rusted up it would be a bear of job to get them off.
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post #7 of 16 Old 02-24-2010, 07:11 PM
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There is a Technical Service Bulletin that exists for this condition. The bulletin just simply instructs us to install exhaust manifold gaskets, which I always do anyways whenever I have one apart.

http://www.yorkdaleford.com/service.html

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....who works at a dealership that now employs SOME half decent looking female employees since they overhauled most of the administrative staff

....but STILL loves hot women with big boobies

....and STILL hates working on E-Series with 6.0L
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post #8 of 16 Old 02-25-2010, 07:02 AM Thread Starter
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If I decide to get this done and have to pay for it with no warranty what is a ballpark price? it seems like it would be a major hassle to do with the rust and access isnt very easy
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post #9 of 16 Old 02-25-2010, 07:18 AM
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Should not be an issue removing the bolts, I've yet to break one upon removal. we use Walker acousti/seal after cleaning of both mating surfaces, works great. whack the up pipe bolts carefully with a cut off tool and replace w/new.

labor is 2.6 hrs for both sides

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post #10 of 16 Old 03-02-2010, 04:00 PM Thread Starter
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I went to the dealer today to make a service appoinment for my wifes Escape and asked about my leaking exhaust manifolds on my truck,they wont cover it under warranty even though I mentioned it before the warranty was up . The service manager suggested replacing the manifolds with new ones and installing gaskets. he said the diesel manifolds come off easier than the gas engine because the gasser has alum. heads. He says he has had to weld a nut on the bolt to have something better to crank on when the bolts are really rusted He says he will give me a price on doing the job when I bring the Escape in next week. Does it seem necessary to use new manifolds?
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