The exhaust manifold collects the exhaust from all of the cylinders and channels it away from the engine through the exhaust pipe. An exhaust manifold that is cracked will no longer work efficiently and you will need to replace it. Leaking exhaust exposes anyone riding in the car to carbon monoxide fumes as well. It does not take very long to replace the exhaust manifold on a Ford. You can do the job yourself in your driveway with some basic tools.
Cool the engine completely before you begin this project or severe burns could result. Disconnect the negative battery cable. Unplug the wiring harness from the electric fan. Remove the fan shroud from the radiator using a wrench. Disconnect the electrical wire from the heated oxygen sensor.
Remove the nut and bolt securing the catalytic converter to the exhaust manifold using a wrench. Remove the bracket bolt from the oil dipstick tube using a wrench. Remove the bolts from the exhaust manifold heat shield using a socket and ratchet. Remove the heat shield from the manifold.
Remove the exhaust manifold by loosening the bolts with a socket and ratchet. Remove the manifold from the engine block. Remove and discard the exhaust manifold gasket. Place a new exhaust manifold and gasket on the engine block. Tighten the retaining bolts with the socket and ratchet. Install the oil dipstick bracket and tighten the nut with a wrench.
Connect the catalytic converter to the exhaust manifold and tighten the bolt and nut using a wrench. Install the exhaust manifold heat shield using a socket and ratchet to tighten the bolts. Connect the electrical wire to the heated oxygen sensor. Install the electric fan to the radiator and tighten the bolts with a wrench.
Plug the wiring harness into the fan. Connect the negative cable to the battery and tighten the terminal nut with a wrench.
It is best to allow the Ford to sit overnight before you begin work on this project. While the surface may appear to be cool, it may actually be hotter closer to the block as you remove parts, resulting in severe burns.