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ATS Manifold Assembly problems

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Anyone using the BD transmission setup?

Hx40

OK- I've read through pages of suggestions and am stuck with putting the stock manifold back on at this point:mad: !!



The da** thing will NOT go together! I have antisieze. I put one in the freezer, one in the oven. I even tried a microwave oven:p . No seriously folks, it will not go. I even tried a rosebud tip with my Oxy/Acety torch. I didn't want to get it too hot for fear of damaging the coating.



Which leads me to this: Is or can the coating interfere with the assembly?? I was under the impression that the coatings weren't all that thick, but maybe this is a thicker than normal coating?



I am concerned about taking any to and sanding because I don't want to screw up the tolerances.



Any suggestions??



Kev
 
ATS

I put my ATS on and a real hard time. We used a mallet and heavy pieces of wood it took about a hour to get them to come to the right way. I think if you have 2 or 3 sets of hands it helps alot. The other thing that might help is to take the stock one and bolt it to the ATS for correct distance between bolts. I'm sorry to hear of your troubles. Eric
 
I had my ATS Manifold ceramic coated too. I had read in an old post that you are not supposed to coat both female and male connections. Both of mine were done too. I felt it was too tight of a fit. I sanded down the male ends (easier of the 2. about 30 seconds worth by hand) and got it to go together w/ freezer and oven. I beat on it w/ a big rubber mallet 'till I was blue-in-the-face. :D
 
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Bill- the male and female ends are coated:( . I guess I'll give some sanding a shot and see if I can get it together. Most have told me that simply heating the center portion of the manifold with a torch is all it takes to get them to mate up.



We'll see about that... ... ... .



Kev
 
ATS man.

Sand the coating off! those manifolds are machine fit ball and socket. they are set up for that clearance only. the ceramic coating is just to thick. you risk cracking the socket by forcing it.

i did mine none coated and it took me less than 2 min. to assemble it. i laid it on a smooth concrete floor w/ the stock man. next to it and put the 1 end piece against a block of wood against a wall, used a dead blow hammer(shot filled) and another block and just tapped it right in place. then turned it around and did same for other end using care as to not force already installed end in farther. i've read many posts on how hard they are to assemble and honestly it was so simple it was silly. Just thought i'd inject my . 02$



Scott
 
Scott- My guess is you got lucky- I know they generally take a bit of persuasion to get them together.



Bill- I was able to get it together after sanding both the male and female ball joint pieces down, and alot of blunt force convincing;) .



Now if only the friggen heater bracket lined up right!



Kev
 
As per previously detailed, sand off the coating. Using wet/dry paper of 400 to 600 grit will work fine. But, only remove the coating! Do not go "a little extra"!



After the bore I. D. s and the corresponding male counterparts have been relieved of the coating, a thin coating of anti-sieze on the male a female halves is required.



Here is how I installed the three pieces of my ATS exhaust manifold:



* obtained the centerline to centerline dimensions of the forward most #1 exhaust bolt hole location and the rearward most #6 exhaust bolt hole location and noted same

* used an old sharpening stone on a flat spot on my garage floor

* cleaned same

* laid down 2 sheets of newspaper

* cleaned the male and female halves with laquer thinner

* applied anti-sieze (in my case I used a very trick ceramic anti-sieze paste from Griot's Garage) to all male and female halves

* placed the center section on the newspaper covered floor

* inserted one end into the socket (one foot holding the center section stationary on the floor while using a Snap-On compothane mallet to "persuade" the outer half into the center section... a little ways)

* repeated the process for the other outboard section

* continued to alternately tap both ends into the center section, measuring against my previously taken centerline to centerline data while at the same time ensuring both ends were installed to equal depths within the center section



This method will ensure that the three flange surfaces will be on the same plane with one another
 
I wouldn't use the old manifold to measure for the ATS manifold set-up.



At least on the 12 valve motors, the manifolds tend to shrink. Bill Lins did that on his and we had a helluva time getting that thing to fit.



I would do as John suggests and take the measurements off the head itself.
 
2002 (24v)



old manifold alongside,

block of wood & dead blow hammer

other end against a block of wood against the wall



no coatings, antisize lubed up just a tad



crank up the country station



get in tune with the beat



took about 15 tunes on each end (probably a hundred of medium taps)



fit perfectly



Bob Weis
 
Thanks to all... ... ... Manifold is in place. I bolted it down to a piece of shop grade 3/4" birch, along with a plate of 1/16" steel, to keep everything in check. I measured off the head of the engine for my marks- I too was warned about using the old manifold.



John- excellent suggestions.



Bottom Line being- the coating can cause problems. Best advice is to tape off the male/female ends. My manifold was silver coated, making it difficult to tell when the coating was off and I was on to the metal. Trial and trial again told me when I got it;) .



Thanks again.



Kev
 
ATS man.

Sorry if i was missleading on the use of the old man.

my 24v was low mi. (20,000k) old man came of w/ no tite spots, so thats how i did the did the alignment for the bolts.

worked fine in my case, but as DkevDog said it sound like i got lucky :D :D glad you got it straightend out Kev, it's a nice piece once installed. hmmm plus i installed my center piece upside down for my twins, wonder if that made a differance? woudnt

think so but ya never know.



Scott
 
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