Intake & exhaust manifold torque

Could your muffler not have a passive fit on the manifold? I had trouble with mine seating and pulling open the #4 exhaust port.
 
Why are you suggesting brass nuts? Ford used steel, the same nuts as for the cylinder head.

If you were going to use steel nuts, you should use anti-seize on the threads to prevent the fasteners from corroding together (c.f. the very common situation of the intake and exhaust having become fused due to corroded steel bolts). And then you're back to the original problem of excessive torque, because 45 ft-lbs on lubricated threads is again probably too much for this application.
 
I guess I've never used a torque wrench on them. I use a 3/8" or 1/2" drive ratchet and working out from the middle tighten them a little at a time until they are snugged up. Then I check them a few times until they settle in.
I leave the 2 bolts holding the intake manifold to the exhaust manifold loose while tightening it down the first time and then snug them up too.
Some day I'll put a torque wrench on them and check the torque value of my snugs.
 
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