Crack in exhaust manifold?

[ageorge]

My 98 12 valve has what appears to be a crack (no leak yet) at the flange where the turbo bolts on. I did a search, but didn't find anything about anyone else having this problem. I am under 100k miles, assume the dealer will replace. Anyone else seen a crack in this location?

 

[Steve Campbell]

I have not personally seen it crack there.

In the posts I have read on cracked exh manifolds, they tend to be in a bell curve(Not the shape of the crack-but where the reports of there occurence are) arount the center of exhaust manifold. Lots of speculation, but MHO is that the most heating and cooling happens in this area and the quicker that "heating and cooling" happens over time leads to the dreaded cracks. Cooler exhaust temps in general and extended cool-down periods before shut-down will make any exhaust manifold last its longest.

 

[Roger rodbolt]

ATS woes.....

ageorge,



My '98 24valve also has a crack on the turbo mounting flange. This is on an aftermarket ATS 3 piece manifold. I haven't bothered to call ATS, this time, because they were no help a year ago on first installation, when the manifold leaked at one of the slip joints. Told me that the manifold wasn't designed for an engine brake and to get it Jet Hot coated for a better interference fit. The leak was there without using the exhaust brake and I fixed it with shim stock. Then about six months ago the turbo flange developed a crack inline with one of the turbo mouning studs but it's not causing a leak a this point. The slip joint is leaking again, so I may ditch the ATS and go back to my perfectly good stock manifold.



I would assume that Dodge would replace your manifold, good luck and sorry for my rant. I rarely complain about a product but I must be having one of those days. :{

 

[ageorge]

Great numbers in your sig. If I were making those kind of numbers I would expect to crack something, but I am talking very near blueprint stock. It appears that I have one of the few factory manifolds that have failed. I have a very good dealer, don't expect any trouble getting it replaced. Thanks.

 

[HEMI®Dart]

If Dodge won't cover the manifold under warranty, I have a stock '94 12V manifold drilled for a pyro someone can have.



I replaced it with an ATS.



Roger, I would think ATS would send you a new one. This is the first time I have heard of a defect in an ATS Pulse manifold.

 

[ageorge]

Thanks!

Thanks HEMIDART for the offer. I should know tomorrow when I visit my dealer. Appreciate the offer. Al

 

[Roger rodbolt]

Hemi,



I also thought ATS would be interested in making it right. The Pulse costs more then their manifolds for the big cam Cummins so you would there should be monies to support the product. I didn't argue with them as they just blew me off and my ATS had ALREADY been Jet Hot Coated. I was very disappointed after the expense of the coating along with all the shipping to get everything redone. I have pyro's pre and post turbo, watch my shutdown temps and have not exceeded 1300 degrees except once (on a dyno run) and my FMS has a recording feature to confirm this. I won the Saturday night truck pull at Scheid's last year and the FMS showed a max egt (preturbo) of 1180!!! I've considered using nickel steel rod and welding up the front joint (which is the only one that leaks)

and I'm sure that I can V-groove out the flange and weld it up. I would preheat it in my fireplace and let it cool for a day in the coals/ashes. What do you think? I've been reading TDR for a few years and have not found a negative post on the ATS, that is why I have been hesistant to post. Maybe I just "lucky".

 

[DRR-24V]

I'mSurprised !

I am surprised to hear this about ATS as I was considering one for my truck. I hope someone from there will respond to this post. That's a lot of money for something that is not perfect.

 

[Garry Verheyden]

Roger,

Have you found out wether the ATS manifold is cast steel or cast iron? I just cut up my ATS manifold to change the angle of the flange and get started in the early stages of my twin turbo set up. I nedd to re weld the flange on soon and was told thier is a big difference in the type of wire(or rod) to use for cast iron vs. cast steel.

If you don't know I will be bringing the manifold to a foundry and they will let me know its composition.

Garry.

 

[JB @ C and L Machine]

Originally posted by Garry Verheyden

Roger,

Have you found out wether the ATS manifold is cast steel or cast iron? I just cut up my ATS manifold to change the angle of the flange and get started in the early stages of my twin turbo set up. I nedd to re weld the flange on soon and was told thier is a big difference in the type of wire(or rod) to use for cast iron vs. cast steel.

If you don't know I will be bringing the manifold to a foundry and they will let me know its composition.

Garry.

Its Cast Iron... . JB

 

[Garry Verheyden]

Thanks John,

Sounds like you have a pretty clean looking truck. When you say jet hot coated, is that a ceramic coating? Does it look like chrome? Did you also do the inside of the exhaust tubing? I'd like to ceramic coat the inside and outside of my head,manifold,turbo housing,and down pipe. I've done the outside of my head so far (I hate rust!) It looks like I have an aluminum head. Doing the inside should reduce egt's and under the hood temps.

Garry.

 

[HEMI®Dart]

Garry,



I had my ATS ceramic coated inside and out. Some companies won't do the inside. Maybe they are concerned about product flake off? Mine came out nice. I also gasket matched the exhaust ports and turbo outlet on the ATS. It takes on an almost chrome like appearance.



http://www.airborncoatings.com/customer/index3.html

 

[Roger rodbolt]

,

Originally posted by Garry Verheyden

Roger,

Have you found out wether the ATS manifold is cast steel or cast iron? I just cut up my ATS manifold to change the angle of the flange and get started in the early stages of my twin turbo set up. I nedd to re weld the flange on soon and was told thier is a big difference in the type of wire(or rod) to use for cast iron vs. cast steel.

If you don't know I will be bringing the manifold to a foundry and they will let me know its composition.

Garry.

Garry,



My understanding is that the ATS is a high quality cast iron casting, with high nickel content. You might check with Enterprise Engine and HVAC as they both have experience in rewelding the turbo flange for twins. I've been reading up on turbo theory in order to build a set of twins for 12 valve play truck and have acquired a HX 40 and H2E for starters. Sound like you are the guy that's getting done though, please keep us informed and good luck!!

 

[ageorge]

Just got back from the dealer, manifold is ordered, along with the gaskets. It is covered under the Cummins emission warranty. Glad I noticed the crack, as I was about to take the turbo off to drill for the pyro port. Now I will get to drill the new one before it goes on.

 

[QRTRHRS]

Mine too.

Gotta jump in here because my ATS leaked also. If you buy this manifold, by all means when the box comes, check the bell fit. As I understand it, the bells should be snug enough to require a rubber mallet to drive together or better yet, put the center in the freezer and the outer sections in the oven. If they slip right together, the fit is too loose.



For now, mine is not leaking. I took some shim stock and shaped it to match the bell and put it together. Guess the gap was tight enough for the carbon to build up.