How to Remove the Exhaust Manifold on a Ford Expedition
The Ford Expedition has been sold since 1997. Although the Expedition has seen many changes over the years, it has retained the same engine options since day one. The Expedition is equipped with either a 4.6L or 5.4L V8 engine; the procedure for removing the exhaust manifold will be the same for both engines.
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Things You'll Need
- Socket wrench set with extension
- Pliers
- Liquid Wrench or similar (optional)
- Shop gloves
Instructions
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1
Turn off the engine in your Expedition, and let it cool for 30 to 45 minutes. The exhaust manifold gets extremely hot; not letting it cool down could result in severe burns.
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2
Unhook the negative (black) battery cable.
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3
Pull out the two mounting bolts from the heat shield. The heat shield is a metallic shield that covers the exhaust manifold. Try to extract the bolts with the socket wrench; use the extension to get better leverage. The extreme engine heat makes these bolts very difficult to remove over time.
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4
Lift the heat shield up and out of the way.
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5
Unhook the vacuum hose attached to the exhaust manifold. The vacuum hose is connected to the EGR valve. Pull it with your hands to remove it.
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6
Remove the two bolts mounting the exhaust manifold to the catalytic converter (on the outside edge of the manifold). As with the heat shield bolts, these will be difficult to pull out. Using the extension will help.
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7
Remove the eight bolts mounting the exhaust manifold. There are four bolts on top and four along the bottom.
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8
Lift the manifold (be careful; it's heavier than it looks) from the engine and remove the gasket.
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Tips & Warnings
Removing the exhaust manifold would be a simple task if the bolts weren't so hard to remove. There is no trick to removing the bolts; it just takes force. You can use a penetrating solvent such as Liquid Wrench or PB Busters to help loosen the bolts. Just spray the solvent around the bolts and let it sit for a few minutes before trying to remove them.
Do not perform this procedure without letting the engine cool. Also, you should wear shop gloves for safety.
