ATS exhaust manifold too short?

[weldingmiller]

Hey guys. I'm trying to install my ATS 4K plus system and hit a roadblock. The exh manifold is too short to get the bolts in by about 1/8 - 3/16. I have read about this problem before but so far have not read anywhere on how they fixed it. Should i oblong the holes with the die grinder, or attempt to lengthen it by tapping it with a rubber hammer? My truck is down until i get this sorted out. Thanks for all the help.

 

[Missouri Mule]

I would think if it is an ATS 2 or 3 piece exhaust manifold it shoudl be adjustable.

 

[MMeier]

I would think if it is an ATS 2 or 3 piece exhaust manifold it shoudl be adjustable.

X 2 on above. Sounds like someone tapped it together a bit too far.

 

[HBarlow]

Yeah, I thought the ATS was a three piece manifold with a slip joint on each side of the center section. It's designed to freely expand and contract at the slip joints isn't it?

I have never seen one and don't know how tight the joints are machined but you should be able to tap each of the two outer pieces with a mallet to widen the overall manifold.

 

[MChrist]

Last year, I wrote about the exact same problem on my ATS manifold. I ended up using a die grinder with a carbide bit to oval out the holes. I tried whacking it with a dead-blow hammer to no avail. Good news is. . once that's figured out, you are half way done.

 

[FFL8N]

I didn't have a problem with mine. I used the stock manifold to line up the holes before I fit it to my truck.

 

[jjdiesel]

A block of wood and a hammer will fix it... easier to do out of the truck. I wouldn't grind or drill anything!

 

[jelag]

I've installed 3 of these with no problem..... in each case a simple dead blow hammer used to tap each side would either expand or contract the manifold to fit...

 

[rscurtis]

I used the BD on my '03. The two sections fit together like a wrist pin goes into a piston- an exace slip fit with no play. I actually installed the rear half on the engine first, then installed the front. Easier to manuever and less weight.

 

[B.G. Smith]

A block of wood and a hammer will fix it... easier to do out of the truck. I wouldn't grind or drill anything!

10-4 on the no grind or drill, if you do that to align the bolt holes the exhaust outlet to the manifold can be mis-aligned. bg

 

[weldingmiller]

thanks for the help guys. I used a 2x4 to adjust it and it worked out well. Then i ran into the problem of the stock bolts not fitting on the bottom of cylinders 3 and 4. I had to use studs. Now i seem to have another problem, on my shakedown run it threw the code P01457. I looked around the forums but have had no luck thus far. Any ideas? I also now have a strange noise in the driveline on take off but thats a whole new topic.

 

[MChrist]

Stock bolts didn't fit bottom side of #3&4? My kit came with Allen heads for those cylinders.
I don't know what code P01457 is off the top of my head, but I do remember having to install a boost fooler after the twin install. Very simple and cheap fix. As far as the strange noise on take-off, the only noise I heard was tire spin!!!

 

[MChrist]

Actually, if I remember correctly, all the stock bolts were replaced with Allen heads from the kit,with the shorter ones going for #3&4.

 

[TCDiesel]

PO1457 is one to many digest...

 

[MChrist]

Hey Todd, I think your computer auto-corrected digits to "digest".

 

[TCDiesel]

OOPS... ... ..... Glad to see you are paying attention:-laf

 

[B.G. Smith]

There is a PO1475 in 99 FCM, something about 5 vot power supply too high. bg

 

[weldingmiller]

Sorry guys, the code was P0147. I cleared it with the quadzilla and so far it has not returned. I double checked the packaging and did not find any of the allen head studs mentioned. I think i figured out the strange noise and vibration. The down pipe only has about 1/16 clearance from the frame now so i'll have to fix it and see what happens. I noticed today that i developed an oil leak on the return line coming off of the bottom turbo. I re-torqued the bolts and will check it again in the morning when i get to work. Overall, i have to say the install was pretty simple except for the missing manifold bolts.

 

[MChrist]

That oil drain sure is fun, isn't it? I think it would have been better to torque it down before mounting the turbo on the exhaust. I used gasket sealer (sticky red stuff) and it worked fine. I did, however, leak at where the drain tube went into the block. Eventually got it fixed.
If your down pipe is that close to the frame, maybe try to loosen the V clamp and crank the pipe around a little. I have well over an inch of clearance.