Six problems related to manifold/header/muffler/tail pipe have been reported for the 2004 Ford F-250. The most recently reported issues are listed below.
Faulty exhaust manifold bolts break off and cause excessive noise, exhaust enters the drivers cabin, vehicle will not pass emissions inspection and is expensive to repair. I have 4 Ford vehicles with this problem. First incident was at around 50,000 miles and 48 months after purchase. Ford refused to make repairs under any portion of the factory warranty. They claim lifetime emissions warranty doesn't cover it, nor the 100,000 powertrain warranty. I have spent over $8000. 00 making repairs to these exhaust manifolds.
Ford f series and super duty pickups with 5. 4 engines. My 2004 Ford F-250 has an issue with leaking exhaust manifolds. When looking into this further while getting pricing, I found out that this was not an isolated issue and that it was a common occurrence due to a mistake in material used for the exhaust manifold bolts. So common that aftermarket suppliers are making replacement kits for the problem. The exhaust manifold attaching studs were made out of a metal that quickly rusts out causing the failure. After the failure, I began to notice exhaust gasses entering the cab of the vehicle through the climate control, which its fresh air intake is in the general direction of the exhaust manifold. I also question the emissions standards because of the exhaust leak not to mention the potential fire risk from heated gasses and flames entering the engine compartment.
Exhaust manifold bolts broken, leading to carbon monoxide (as well as other exhaust gases) being released into passenger compartment.
Exhaust manifold bolts rusted/corroded & broken off + rust/corrosion related crack in exhaust manifold itself. This is obviously an ongoing problem with no specific date as to when it happened only when it was discovered. I believe this to be an emissions issue.
Exhaust leak entering drivers compartment had this truck in shop four times have been tld to many ahead so it will be days maybe longer think they are wanting the warranty to run out but this leak can cause health problems are maybe an accedent. There has been a lot of the diesel pickups with this problem so I think it needs to be repaired under warranty no matter what the mileage is.
When turning on the air conditioner or heater strong diesel fumes enter the passenger cabin. Dealer will replace the flex pipe on the back of the engine from the manifold.