Rusty cast-iron exhaust manifold held in front of a gray Ford Br…

Note that the crappy exhaust manifold gasket didn't even touch half the lip of the manifold, which is why it blew out here.



To check for flatness, I cleaned this face with a 12" double-cut file across 3 ports at a time. It was still true. If it had been warped, I'd have had it machined flat.

Left F4TZ9430E; Right F4TZ9431E; pair cheap new imports are OK (do NOT use gaskets)
High-temperature silicone
Manifold-to-head bolt: short 392016S4301; short w/short stud 389201S; long 381732S; long w/long stud 388469S; long w/short stud 386197S; (Dorman left set 03405; right set 03407B or 03407)
Spark plug heat shield F2UZ12A406A/F4TZ12A406BA
Manifold-to-flange stud: 391104S2; nut 375636S7; (Dorman 03135)
Manifold-to-EGR (5.8L only) tube: F0TZ9D477A (Dorman 598101, cheapo)

Owner caption November 2009 · Photo 61 of 434