Exhaust manifold won't line up....HELP!

[AMink]

I have some soot blowing out between 5 and 6 and 1 and 2. I am also getting some weird sounds with and without the Jake brake on so I decided to put new gaskets on. Got all the old studs out, no problems (except for the stupid heater hose bracket). Problem now is getting the studs back in. I got 1, 2, 3, and 5 in. 4 and 6 won't line up. I've tried some gentle prying but it won't move enough to get the studs in the block. The other studs are not tightened down.

I really don't want to have to buy a new manifold. I've just done ball joints, new belt, shocks, and some other minor maintenance stuff and if I tell my wife I need to drop another chunk of cash I'll be in trouble. . I can't believe all this happens at once!

 

[seafish]

Definite problem with the oem one-piece manifold is shrinkage/expansion/movement over extended time... while you might be able to oversize the holes in the manifold, that will only mask the problem... unforutnately you are likely looking at getting a new manifold, oem or aftermarket. I DO have an oem 5. 9 in more then decent shape that I could sell you for $50 plus shipping. Pm me if interested and I can send pics and measurements. Of course, an aftermarket 2 piece, or Steed Speed billet, will aslo solve the problem permanently, though at much higher cost.

 

[Joseph Donnelly]

I agree that you probably need a new manifold. You can take it off and measure its length between bolt holes for #1 and #6 to be sure.

 

[JWiegel]

Replacw the manifold and bolts,

 

[rscurtis]

I agree. Keep in mind that the manifold may have shrunk in one direction, and may be out-of-plane where it mates to the head. Replace it now or do the job again when you do replace it.

 

[Wingate]

I agree. Keep in mind that the manifold may have shrunk in one direction, and may be out-of-plane where it mates to the head. Replace it now or do the job again when you do replace it.

X2!!... Yep, there is a reason you had an exhaust leak. Buy a decent aftermarket multipiece one.

 

[jelag]

When I had the exhaust manifolds fail on the trucks that I own... I replaced them with either the ATS or BD manifolds. .
Both are multi-piece units that have braces between the ports... I've had the ATS unit off the head of my 05 and had no problem with it going back on...

 

[Bob4x4]

Or maybe kick it up a notch like this from AFE with a lil elbow grease
#ad

 

[AMink]

BD manifold in the garage, waiting to be introduced to the engine. It would be nice if these things came with studs and gaskets. Any tricks to getting the v-clamp between the turbo and exhaust brake off? Should I use anti seize on the bolts?

 

[Joseph Donnelly]

Leave the turbo alone, just take the manifold stud nuts off. Reuse the stock 12 mounting bolts and spacers. Double nut the studs after removing the manifold, whack with a brass hammer while turning the inner nut to remove the studs. Never seez the threads. The gaskets are cheaper at Cummins than at the dealer; 2003-4 gaskets are one layer and cheaper than the later multi-layer ones. Even NAPA etc. might carry gaskets.

 

[rscurtis]

I realize that I'm spending other peoples' money here, but as long as you're this far into it, a Killer B might be a nice addition to your truck.

 

[Gonzo 1066]

Just as a side note, I had the same issue with the stock manifold on my 04. 5. I replaced it with a ATS manifold 5-6 years ago, I recently had to do a head job on the truck and the ATS manifold was warped and had to be resurfaced. The machine shop that did the resurfaceing said the manifold was quite a way out of flat and that the cast was VERY HARD material. My truck only tows in the mountains of the west and I do have a tuner on it.