Four problems related to manifold/header/muffler/tail pipe have been reported for the 1997 Ford F-250. The most recently reported issues are listed below.
I have a 1997 Ford f250hd with the 5. 8l engine and 78,000 miles. I noticed an exhaust leak and decided to install exhaust manifold gaskets to cure the problem. However, when I started the job I noticed that there were broken exhaust studs that had broken flush with the head. After removing the manifolds from the heads I also found multiple cracks in the manifolds, one almost completely around the right manifold. After contacting the local Ford dealership I was told that the problem was a common one for my year and engine but was only taken care of while there was warranty. I was told that the casting for the manifolds for those years was weak.
Problems with oil pan, brakes, transmission and exhaust manifold. The front end casing cracked. The oil pan, brake and transmission lines rusted out. The bolt heads rotted off from the exhaust manifolds, and the heads cracked as a result. The rear end cap rusted along with the pollution control valves. The left front tire tilted as a result in a cracked front end housing leaving a 1" gap. A front tire alignment was needed.
The exhaust pipe heat shield was in contact with the metal transmission fluid tube from the transmission to the radiator. Over a period of time the shield wore a small hole in the tube, resulting in a pinhole, which caused the transmission fluid to be released under pressure directly onto the exhaust pipe.
Consumers vehicle will not pass future vehicle inspections because exhaust pipe exits on the side (design).