Having problems with your 1996 Ford F250 Crew Cab ?

How to change an exhaust manifold leak 7.5L - 1996 Ford F250 Crew Cab

Posted / edited by AnonymousUser on : 22-01-2018

Answers :

Right-Hand
\015\012Removal
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  1. \015\012Remove spark plug heat shield (12A406).
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  1. \015\012Remove distributor to spark plug wires (12286) using Spark Plug Wire Remover T74P-6666-A.
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    1. \015\012Disconnect muffler inlet pipe.
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    1. \015\012If equipped with secondary air injection, disconnect the secondary air injection check valve tube (9B480).
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    1. \015\012Remove attaching bolts and right exhaust manifold (9430).
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    1. \015\012Inspect joint faces for signs fo exhaust leaks, cracks or any defect that would make exhaust manifold unfit for use
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\015\012Left-Hand Removal
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\015\012 1. Remove oil level indicator tube (6754).
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  1. \015\012Remove spark plug heat shield.
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  1. \015\012Remove distributor to spark plug wires using Spark Plug Wire Remover T74P-6666-A.
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    \015\012
  1. \015\012Disconnect EGR valve to exhaust manifold tube (9D477). If equipped with air injection, disconnect the secondary air injection check valve tube.
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  1. \015\012Disconnect muffler inlet pipe.
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  1. \015\012Remove attaching bolts and exhaust manifold (9431).
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    \015\012
  1. \015\012Inspect joint faces for signs of exhaust leaks, cracks or any defect that would make the exhaust manifold unfit for use.
\015\012Installation
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  1. \015\012Clean mating surfaces of right exhaust manifold or left exhaust manifold and cylinder head (6049). Clean mounting flange of right exhaust manifold or left exhaust manifold and inlet pipe(s). Clean mounting surface for air injection tube or right exhaust manifold. Apply light film of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to right exhaust manifold or left exhaust manifold.
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  1. \015\012Position right exhaust manifold or left exhaust manifold on cylinder head. Install attaching bolts and washers, starting at fourth bolt hole from front of each right exhaust manifold or left exhaust manifold. Tighten bolts to 34-47 Nm (25-35 lb-ft), working from center right to both ends.
  2. \015\012
      \015\012
    1. \015\012Position inlet pipes to right exhaust manifold or left exhaust manifold. Install attaching nuts and tighten to 34-47 Nm (25-35 lb-ft).
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      \015\012
    1. \015\012Position the secondary air injection check valve tube and the secondary air injection tube gasket (9C435) at rear of right-hand exhaust manifold. Install attaching bolts and tighten to 19-25 Nm (14-18 lb-ft).
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    1. \015\012Attach the secondary air injection manifold tube (9B449) to left-hand exhaust manifold fitting (located under EGR tube). Tighten nut to 30-40 Nm (22-30 lb-ft).
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    1. \015\012Attach the secondary air injection check valve tube to rear of right-hand cylinder head. Tighten bolts to 75-85 Nm (56-62 lb-ft).
    2. \015\012
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      1. \015\012Connect EGR valve to exhaust manifold tube to left exhaust manifold, if removed. Tighten nut to 53-72 Nm (39-53 lb-ft).
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      1. \015\012Install spark plug heat shield and distributor to spark plug wires.
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      1. \015\012Install oil level indicator tube to left exhaust manifold, if removed. Tighten nut to 13-24 Nm (10-18 lb-ft).
      2. \015\012
      3. \015\012Start engine (6007) and check for exhaust leaks.
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\015\012Hope this helps you...WF †
Also, I have a 5.0 in my truck and I needed to change my passenger side (which just so happens to be the tightest spot) and to make it alot easier, I took out the fender well and i got right in front of it! Saved alot of scrapes! Only downside is you have to unhook whatever is mounted on the fender well, but it usually is worth it.
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