How much does it cost to replace the exhaust manifold on a Ford Expedition?
On most Ford Expeditions, replacing an exhaust manifold is a significant repair that typically costs between roughly $800 and $3,000, depending on engine type, how many manifolds are affected, and the local labor rate.
Exhaust manifolds channel exhaust away from the engine and can crack with heat cycles, especially on turbocharged EcoBoost engines. The Ford Expedition has used a few different powertrains over its generations, including naturally aspirated V8s and the 3.5L EcoBoost V6, which affects both the replacement parts and the complexity of the job. This article explains what drives cost, provides typical ranges for common configurations, and explains what to expect during service.
What drives the price
The price of an exhaust-manifold replacement hinges on several factors. The following list highlights the main drivers, including engine configuration, number of manifolds, and shop rates.
- Engine configuration and number of manifolds: The Expedition uses two exhaust manifolds (one per bank) on V8 configurations, and EcoBoost models also have two manifolds connected to turbo equipment. Replacing both banks doubles parts and labor versus a single bank.
- Turbocharged vs naturally aspirated: Turbo engines require handling turbo hardware, up-pipes, and more complex routing, increasing both parts cost and labor time.
- Parts choice: OEM vs aftermarket/manufactured alternatives, and whether the manifold includes catalytic components or needs separate gaskets and up-pipes.
- Labor costs and location: Labor rates vary by region and shop. Urban areas tend to be higher than rural areas and dealer shops usually bill more than independent shops.
- Associated components: Gaskets, studs/bolts, heat shields, oxygen sensors, and possibly the catalytic converter components can add to the bill.
- Condition of the engine and bolts: If bolts are corroded or studs break, extra time and specialized equipment are required, raising labor costs.
In summary, the price is driven by the engine type, number of manifolds, component combos, and local labor economics. Obtaining a written estimate that itemizes parts and labor is essential.
Typical cost ranges
Prices vary by model year and engine configuration. The following ranges reflect common Expeditions in the United States, with two separate scenarios for older non-turbo and newer EcoBoost engines.
Expeditions with naturally aspirated V8 engines (e.g., 5.4L/4.6L)
For two exhaust manifolds on a non-turbo V8 Expedition, parts and labor typically fall within these ranges:
- Parts (two manifolds, gaskets, and related hardware): approximately $500–$1,200
- Labor: about 4–8 hours total at typical shop rates $90–$140 per hour: roughly $360–$1,120
The combined total for a full replacement of both manifolds on a naturally aspirated Expedition generally runs about $860 to $2,320, depending on whether OEM or aftermarket parts are used and the shop's hourly rate.
Ford Expeditions with the 3.5L EcoBoost turbocharged engine
Turbocharged engines add complexity. For two manifolds with turbo connections, expect:
- Parts (two manifolds with up-pipes and related hardware): roughly $1,000–$2,000
- Labor: typically 6–12 hours total at $100–$150 per hour: about $600–$1,800
The all-in cost for EcoBoost Expeditions commonly falls in the range of roughly $1,600 to $3,800, though some jobs can exceed that with complications or if a dealer performs the work.
Note: In both cases, if the catalytic converter is integrated in the manifold, or if any bolts/studs are seized or broken, or if the technician replaces additional exhaust components, the price can rise substantially.
DIY vs professional service
Replacing exhaust manifolds on a Ford Expedition is a mechanically involved job that requires engine access, careful torque, and treatment of hot-rodded turbo systems on EcoBoost models. For most owners, a professional mechanic with a good lift and proper tools is advised. A DIY approach risks accidents, improper torque, and incomplete sealing, which can lead to leaks, poor performance, or fire hazards in turbocharged engines.
Before committing, get multiple written estimates and ask about warranties on parts and labor. Also confirm whether the price includes gaskets, mounting hardware, studs/bolts, and a road-test after repair.
What to expect during the repair process
Here is a high-level view of the steps involved in replacing exhaust manifolds on a Ford Expedition:
- Diagnosis to confirm which manifold(s) need replacement and check for leaks or misfires.
- Gain access by removing components that block the manifolds and disconnecting exhaust connections.
- Remove the old manifolds, clean mounting surfaces, and inspect turbo piping or up-pipes on EcoBoost models.
- Install new manifolds with new gaskets and hardware; torque to specification; reattach exhaust and sensors.
- Reinstall any removed components, clear codes if needed, and perform a road test to verify proper operation.
Expect a more thorough job if there are corroded bolts or seized hardware. A reputable shop will also inspect neighboring heat shields and oxygen sensors and may replace them if necessary.
Summary
Exhaust-manifold replacement on a Ford Expedition typically ranges from roughly $800 to $3,800, influenced by engine type, personnel rates, and whether both banks are involved. Non-turbo V8 models generally cost less than EcoBoost turbocharged versions, but both scenarios benefit from clear, itemized quotes and a warranty on parts and labor. If you notice loud exhaust, misfires, or a DPF-related warning light, prompt diagnosis is advised to prevent further damage.
