How to Replace Exhaust Manifolds 2009-2010 Ford F-150 (5.4L V8)

Introduction

This tutorial provides a comprehensive guide on how to replace the exhaust manifolds on a 2009-2010 Ford F-150 equipped with a 5.4L V8 engine. Following these steps will help you successfully install new exhaust manifolds, ensuring that your vehicle operates efficiently and effectively.

Step 1: Prepare the Vehicle

• Safety First: Ensure you are wearing safety glasses and gloves to protect yourself during the process.
• Lift the Vehicle: Use a floor jack to raise the front of the truck and secure it with jack stands.
• Disconnect the Battery: Remove the negative battery cable to prevent electrical issues.

Step 2: Remove the Exhaust Components

• Locate the Exhaust Manifold: Identify the manifold on both sides of the engine.
• Remove Heat Shields: Use the appropriate socket size (typically 10mm or 12mm) to unbolt the heat shields from the exhaust manifold.
• Disconnect the Exhaust Pipe:
  • Use a 15mm socket to unbolt the exhaust pipe from the manifold.
  • If necessary, use a pry bar to gently separate the pipe from the manifold.

Step 3: Remove the Old Exhaust Manifold

• Unbolt the Manifold:
  • Use a combination of sockets (12mm, 13mm, and 14mm) to unfasten all bolts securing the manifold to the engine.
  • Use a twist socket or extractor socket if bolts are stripped.
• Remove the Manifold: Carefully lift the old manifold off the engine, ensuring no debris falls into the engine bay.

Step 4: Prepare for New Manifold Installation

• Clean the Surface: Use a wire brush and sandpaper to clean the mounting surface on the engine block. Ensure there are no old gasket residues.
• Inspect Gaskets: Check the condition of the gaskets. If they are worn, replace them with new ones.

Step 5: Install the New Exhaust Manifold

• Position the New Manifold: Place the new exhaust manifold onto the engine block.
• Secure the Manifold:
  • Hand-tighten the bolts to hold the manifold in place.
  • Use a torque wrench to tighten the bolts to the manufacturer's specifications, typically starting from the center and moving outward.

Step 6: Reconnect Exhaust Components

• Reattach the Exhaust Pipe:
  • Align the exhaust pipe with the new manifold.
  • Use a 15mm socket to secure the pipe to the manifold.
• Reinstall Heat Shields: Bolt the heat shields back in place using the appropriate socket size.

Step 7: Final Checks

• Reconnect the Battery: Reattach the negative battery cable.
• Start the Engine: Turn on the vehicle to check for leaks or unusual noises.
• Inspect for Issues: Make sure everything is securely fastened and functioning properly.

Conclusion

Replacing the exhaust manifolds on a Ford F-150 can be a straightforward task if you follow these steps carefully. Remember to prioritize safety by using protective gear and ensuring the vehicle is securely lifted. If you encounter any issues, refer back to this guide or consult a professional mechanic. With your new exhaust manifolds installed, you can enjoy improved vehicle performance.