Buy Ford Bronco Exhaust Manifolds

The exhaust manifold bolts to the engine block and collects hot gases from every cylinder, then funnels them into one pipe. This keeps fumes away from the cabin and lets the catalytic converter clean them up. Wikipedia

Because the Bronco's newer turbo engines tuck the turbocharger right after the manifold, a tight seal here also helps the turbo build boost quickly for more power. Cars.com glossary

Early-generation Broncos use thick gray cast-iron manifolds. Cast iron is heavy, but it handles heat well and stays quiet. A study showed that adding just 2 % nickel doubles hardness and boosts fatigue life. ResearchGate paper

Modern 2.3 L and 2.7 L EcoBoost engines often pair a stainless-steel tubular header that is lighter and flows better, helping fuel economy and low-end torque. Autoprotoway manufacturing overview

• Ticking on startup-a sharp tap that fades as the metal warms up. Rainbow Muffler blog
• Exhaust smell in the cab, which can be dangerous because of carbon monoxide. Bronco Sport owner report
• Loss of pep or poorer gas mileage-leaks spoof the oxygen sensor and make the computer dump in extra fuel. Rainbow Muffler blog

Heat shields keep wires, hoses, and the firewall from overheating. A quick primer on shield types (rigid aluminum, flexible foil, and wrap) is on Wikipedia's heat-shield page.

Service shops add that good shields also cut noise and cabin temps. Lou's Car Care article

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• 2.3 L turbo manifold-to-head: 20-30 ft-lb, tighten in two steps. Merkur Club spec sheet
• Classic 5.8 L: 18-24 ft-lb on clean threads. (Full Size Bronco)
• Always replace the metal-ring gasket noted in the latest NHTSA bulletin for 2.3 L and 2.7 L trucks. NHTSA PDF

Tip: Soak rusty studs with penetrating oil overnight, then warm the engine briefly before removal to cut the risk of broken bolts.

Swapping to a stainless header with equal-length runners trims back-pressure and can free up 10-15 hp on naturally-aspirated vintage Broncos. Wikipedia header notes

On new EcoBoost models, port-matched casting and ceramic coating hold heat in the turbine, helping the turbo spool sooner for snappier off-road throttle. Autoprotoway manufacturing overview

• Engine-valve recall (2024-2025)-covers some 2021-2022 Broncos with 2.7 L and 3.0 L engines; a broken valve can mimic exhaust leaks or misfires. Reuters report
• TSB 25-2206 (May 2025)-false check-engine light tied to exhaust pressure sensors on certain 2.7 L trucks; dealers update software and inspect manifold joints. Bronco6G summary

• Keep all three mounting points-head flange, crossover pipe, and turbo flange-tight. Loose joints were the root cause in one owner's clamp leak. Bronco6G thread
• Check heat shields after heavy off-roading; dents can press on the manifold and cause hairline cracks. Lou's Car Care
• If you smell exhaust, stop driving and investigate-carbon-monoxide poisoning is silent. Rainbow Muffler

Q: What does the exhaust manifold actually do?
A: It gathers exhaust gas from each cylinder and sends it into one pipe so the catalytic converter can clean it. Wikipedia

Q: Is the manifold the same as a header?
A: "Header" usually means a high-flow tubular replacement; both do the same job.

Q: Why do manifolds crack on turbo Broncos?
A: Turbo heat plus off-road vibration stress the thin cast steel; loose studs amplify the issue. Bronco Sport owner report

Q: Can I drive with a small leak?
A: It's risky-fumes can reach the cabin and the leak can burn nearby wires. Get it fixed fast. Rainbow Muffler

Q: What bolts should I replace during service?
A: Ford's bulletin lists new one-time-use studs and flange nuts for 2.3 L and 2.7 L engines. NHTSA PDF

Q: Do I need a gasket on old cast-iron manifolds?
A: The factory design seats metal-to-metal, but many techs add a thin composite gasket to stop future leaks.

Q: What torque should I use?
A: Classic 302/351 engines: 18-24 ft-lb. Modern 2.3 L turbo: 20-30 ft-lb in two stages. (Full Size Bronco, forum.merkurclub.com)

Q: Will a ceramic-coated header void my warranty?
A: A header alone may not, but any part that changes emissions can affect coverage-check local laws first.

Q: Why does the Bronco Sport's manifold smell after hard pulls?
A: A loose turbo-to-down-pipe clamp lets hot fumes escape until metal expands and seals. Bronco6G clamp tip

Q: How long should a manifold last?
A: Cast iron can last decades; thin stainless turbo housings may need replacement around 120 k miles if overheated.

Need more help? Use the links above for deeper reading, and keep your Bronco breathing free and clear!