Ford E4TZ-9426-D Exhaust Manifold Assembly

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To remove the exhaust manifold from carbureted models, first take off the air cleaner, intake duct, and heat duct if working on the right side. For the left side on a 351M or 400 engine, remove the engine oil filter and cruise control bracket if present, along with the oil dipstick and tube assembly for all engines except the 460. If the vehicle has a column selector and automatic transmission, disconnect the cross lever shaft for clearance. For EFI models, remove the air cleaner and intake duct for the right side manifold, then take off the upper intake manifold-to-exhaust manifold support bracket for 5.0L and 5.8L engines, followed by the engine or transmission dipstick tube bracket as applicable. Also, remove the EGR tube for the 5.8L engine on the right side and for the 7.5L engine on the left side, along with the engine oil dipstick tube bracket if equipped. For all models, disconnect the retaining bolts holding the exhaust pipe(s) to the exhaust manifold(s), remove the spark plug wires and heat shields if equipped, and then take off the exhaust manifold retaining bolts, lifting eyes, and nuts, noting any locking tabs that need to be bent down before removal. Keep track of parts location and bolt lengths for reinstallation. After removing the exhaust manifold, clean the mating surfaces of the exhaust manifold and cylinder head, as well as the mounting flange of the exhaust manifold and the exhaust pipe. For installation, apply graphite grease to the mating surface of the exhaust manifold and cylinder head, install a new exhaust manifold gasket for the 5.8L Lightning, position the exhaust manifold on the head, and install the attaching bolts, tightening them from the center to the ends. If equipped, install the spark plug heat shields and lifting eyes, then complete the installation in reverse order of removal. Finally, start the engine and check for exhaust leaks.

First, at the left (driver's) side proceed with the removal of the oil level dipstick tube support bracket. If the vehicle has speed control remove the air cleaner assembly and detach servo chain at the carburetor end. Then, take out the servo bracket attaching bolts and nuts and place the servo/bracket assembly off to the side. If so provided, remove the connections of the oxygen sensor at the electrical connector and the spark plug connections. Lift the front of the vehicle and put on jackstands, and then removed the manifold to exhaust pipe attaching nuts. Once the car is off the jackstands, lower it and then proceed to take out the exhaust manifold bolts, and the manifold. In installation, unscrew the pilot bolt in an opposite manner to the removal procedure; however, install the pilot bolt first which is the lower front bolt on cylinder number 5. Remember that slight warpage is present in the exhaust manifold and this could cause misalignment of the bolt holes in the head and that of the manifold; if this happen, simply elongate the holes in the exhaust manifold as far as is necessary but must not elongate the pilot hole. On the right side then begin by leaning over the passenger seat the air cleaner assembly and the heat tube should be removed; next the thermactor hose should be disconnected from the downstream air tube check valve. Take out the downstream air tube bracket attaching bolt at the rear of right cylinder head and disconnect the coll secondary wire from the coil as well as the connection of wires to spark plugs. Dealer says to take out the spark plugs and outer heat shroud, raise the front end of car by jacking and supporting on stands. If so fitted, pull off the transmission dipstick tube followed in turn by the manifold to exhaust pipe attaching nuts. Following the removal of the jackstands and lowering the vehicle and taking out bolts that attach the exhaust manifold, then you will be able to remove the manifold together with the inner heat shroud and the EGR tube. For reassembly, the procedure is the reverse of disassembly; if, as a result of bolt hole misalignment, the pilot hole (the lower rear bolt hole on #2 cylinder) is elongated, stop at once.

Coat the mating surfaces with graphite grease. Place the exhaust manifold over the studs on the intake manifold. Connect the two with the lock washers and nuts. Tighten the nuts finger tight.

Remove the oil level dipstick tube support bracket.

Coat the mating surfaces with graphite grease. Place the exhaust manifold over the studs on the intake manifold. Connect the two with the lock washers and nuts. Tighten the nuts finger tight.

Remove the EGR tube.