If the exhaust manifolds on your 2004 Ford F150 are cracked or leaking, dangerous fumes can escape into the passenger compartment. You need to replace such a manifold to prevent damage to your health and the environment. The manifolds connect the engine at the cylinder heads to the exhaust pipes. Keep in mind that there are slight differences in the process depending on whether your vehicle has a V6 or V8 engine.
Instructions
Removal
- 1
Disconnect the truck's negative battery cable.
2Raise the truck on its rear end using a floor jack. Support with jack stands.
3If your truck is a V6, disconnect the electrical connector for the oxygen sensor by hand. The sensor is located on the manifold. On a V8, disconnect the bracket for the power brake booster vacuum hose, loosening the nut at the manifold's end with your wrench.
4Remove the nuts connecting the manifold to the exhaust pipes using a wrench and pull the manifold off the pipes.
5Unscrew the nut for either the EGR tube or the oil dipstick tube support with your wrench and remove that component from the manifold. Each manifold contains one of these components.
6Remove the manifold's mounting nuts with the wrench and separate the manifold from the cylinder head.
7Scrape away all traces of carbon and gasket material from the cylinder heads using a gasket scraper.
Installation
- 8
Place a new gasket onto the cylinder head studs and then place the new manifold on the studs. Apply the mounting nuts.
9Tighten the nuts with your wrench, alternating between the top and bottom rows and moving from the front to the rear.
10Reconnect the EGR tube or oil dipstick tube using their nuts and the wrench. For the EGR tube, apply a small amount of anti-seize compound to the threads before connecting it.
11Connect the exhaust pipes to the manifold with their nuts and wrench.
12Reconnect the brake booster vacuum hose or the oxygen sensor electrical connector.
13Lower the truck off the jack stands and reconnect the battery cable.
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