Exhaust manifold bolt failure. - Ford Transit USA Forum
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post #1 of 25 (permalink) Old 08-20-2019, 07:21:PM Thread Starter
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Exhaust manifold bolt failure.

Or "the Scream" part II.

What I thought was a belt/pulley problem got worse. heavy popping/chirping on startup, right hand side of the engine goes away after a few minutes. Still the screeching under load. More internet research until I came upon stories about exhaust manifold gasket failures as a result of bolts snapping.

Soooo.... I went in there and poked around. Good news is that this is about the only part of the engine you can get to. Bad news is, my warranty expired 3900 miles ago and I bet this is not covered under the power train warrantee. (Early 2017 vehicle)

Last bolt on top, all the way in the back..... Note carbon deposits. Calling dealer tomorrow.
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post #2 of 25 (permalink) Old 08-20-2019, 08:41:PM
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Any good mechanic should be able to pull the broken bolt with an extractor. No dealer required.
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post #3 of 25 (permalink) Old 08-20-2019, 10:11:PM
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Keep us posted on the fix and what it runs.

Disassembly to access the bolt and be able to replace the gasket, then reassembly. I'd be interested to know what the quoted book hours are on this.

Is this, by chance, a part that is exposed to the under-hood drainage system?
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post #4 of 25 (permalink) Old 08-20-2019, 10:16:PM
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I wonder if extracting the broken bit and putting a new bolt in would be adequate to seal it up and stop the screaming? Taking off the entire exhaust manifold and putting in a new gasket seems like a whale of a job, maybe even requiring removal of the engine from the van.

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post #5 of 25 (permalink) Old 08-20-2019, 10:18:PM
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Originally Posted by dustboy View Post
Any good mechanic should be able to pull the broken bolt with an extractor. No dealer required.
Do you think they will be able to pull it without removing the manifold though? I've used a bolt extractor a few times and this scenario seems quite challenging.

Imo this is a scenario where the warranty should cover it, its so close to the time it expired and such a weird thing to fail I would expect them to have good will.

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post #6 of 25 (permalink) Old 08-20-2019, 10:19:PM Thread Starter
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I'm not a bad mechanic myself, so if Ford doesn't want to live up to it's moral obligations I'll do it myself. And before we unleash a crap storm over what those obligations may or may not be, yes I know....the end of your warrantee is the end of your warrantee. You signed it, you own it. That said..... exhaust manifold bolts snapping at 36001 miles is poor quality, plain and simple. They should own it.

I don't think this is directly affected by the drainage system. I think it's poor design in that the bolt is out there way by itself and there's a LOT of heat going through that manifold. Simply too much load on that bolt. It's the one on the far right.

I'll post what the dealer has to say.
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post #7 of 25 (permalink) Old 08-20-2019, 10:23:PM
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From a mechanical engineering standpoint, a multi bolt interface like this should never fail. I don't think any engineer in their right mind would try to understructure this critical part to save a few cents on cost.

My money is on a faulty or overtightened bolt, only time will tell if the issue is actually a design flaw and therefore common.

That said, a faulty bolt should be covered by the manufacturer.

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post #8 of 25 (permalink) Old 08-20-2019, 10:54:PM Thread Starter
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From the amount of Youtube vids and discussions on the Ecoboost (Mostly on the F-150 side) this IS very much a common issue and has been for years.


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post #9 of 25 (permalink) Old 08-20-2019, 10:56:PM Thread Starter
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There's a very good video on the subject here. The engine does not have to come out, the turbo does have to come off, and it's got exhaust, intake air, oil and coolant connections. Oh joy.

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post #10 of 25 (permalink) Old 08-21-2019, 12:49:PM Thread Starter
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OK, my day just got a lot better. Dealership was courteous and helpful engaging multiple levels of advisors and supervisors. First off they confirmed my assessment of the problem. (They also agreed this was bullcrap engineering, although not in those words.) Then they told me they considered it covered under the powertrain warrantee, although there was also talk of the emissions warrantee..... Either way, I don't care as of now they are paying for it.

And they sent me home in a loaner.....

Much better, although I am painfully aware this issue will come back again at some point.
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