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Ford F-150 Exhaust Manifolds Can Crack and Cause Leak - 69 reports. Learn about this problem, why it occurs, and how to fix it. Is there a recall on this? It is a 2007 expedition, 5.4L. Like this comment? Sign in or register to let us know! Register Sign In (1) Report. 2008 Ford F-150. Updated Differential Clutch Kit Available if Rear.
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Plastic can be 'welded' using a plastic welding kit. They sell them at harbor freight tools, and other places.
It will melt the plastic and you can add more plastic material during the process, to bond the two points back together and fill it in, then sand it smooth and repaint if desired. You can use the same setup to fill small holes.
Just put something behind the hole so the material doesn't just sag or flow out the back, fill it in, and sand smooth and paint. For a less attractive repair, just to keep it from spreading, drill the end of the crack so it has a nice smooth round hole, then drill small holes on both sides of the crack, and use wire ties to hold the area together, and keep it from flexing and cracking more.
It's a common practice in the motorcycle/atv world to fix plastics, but I don't recommend it.