Cracked Exhaust Manifold

[Cattletrkr]

Here's the bracing on the engine side:

#ad


And here's the bracing on the outside... passenger side.

#ad

 

[Cattletrkr]

This really isn't that hard of a project, if you do it right. I tried last night on a warm/hot engine and that was a waste of 3 hours. I got 14 of the 16 bolts out and had to turn back. Tonight I was able to let it sit for 5-6 hours before starting and I took a couple detours so nothing was more than warm to the touch.

The heater hose bracket it just retarded. They could have easily made it to mount on any of the three other studs close by but instead they decided to add dang near an hour to the project. I managed to save it and get it bolted back up but I really don't see where cutting it off would cause any issues.

I do have some work left. After I was all done I fired it up and everything was cool until I hit the exhaust brake. Leaking VERY BAD somewhere. I think it's cylinder #6 but I'm not sure. I planned on retorquing it tomorrow anyway. Maybe take it into town and then let it cool down and see what happens.

The biggest headscratcher was when I picked up the old gaskets off the floor... I had 9 of them... I thought this was only an I-6. Some of them fell apart. They are three layered gaskets. At first I thought they shimmed each cylinder separately at the factory. Then I opened the new gasket packages and found they were all three layers. No biggie.

I do have one question for the experts. What is the proper method for torquing the manifold?

 

[Cattletrkr]

Whew!!! Anybody gotta beer???

 

[TCDiesel]

Here it is...



INSTALLATION

(1) Using new gaskets, install the exhaust manifold

and gaskets. Install the bolts and spacers and

tighten the bolts in the sequence shown in to 43 N·m

(32 ft. lbs. ) torque.

(2) Retorque the four center bolts.

(3) Install heat shield and torque bolts to 24 Nm

(18 ft. lbs. ).

(4) Install cab heater tube.

(5) Install exhaust manifold bolt retention straps.

(6) Install the cab heater return hose to the manifold

bolt stud. Tighten the nut to 24 N·m (18 ft. lbs. )

torque.

(7) Install the turbocharger and a new gasket.

Apply anti-seize to the studs and then tighten the

turbocharger mounting nuts to 43 N·m (32 ft. lbs. )

torque. (8) Install the oil drain tube and a new gasket to

the turbocharger. Tighten the drain tube bolts to 24

N·m (18 ft. lbs. ) torque.

(9) Pre-lube the turbocharger. Pour 50 to 60 cc

(2 to 3 oz. ) clean engine oil in the oil supply line fitting

on the turbo. Rotate the turbocharger impeller

by hand to distrubute the oil thoroughly.

(10) Install and tighten the oil supply line fitting

nut to 24 N·m (18 ft. lbs. ) torque.

(11) Position the charge air cooler inlet pipe to the

turbocharger. With the clamp in position, tighten the

clamp nut to 8 N·m (72 in. lbs. ) torque.

(12) Position the air inlet hose to the turbocharger.

Tighten the clamp to 8 N·m (72 in. lbs. ) torque.

(13) Raise vehicle on hoist.

(14) Connect the exhaust pipe to the turbocharger

and tighten the bolts to 34 N·m (25 ft. lbs. ) torque.

(15) Lower the vehicle.

(16) Connect the battery negative cables.

(17) Start the engine to check for leaks.

 

[JDerrick]

Oo. Beer no VODKA YES !!!!!! whoa yukk i'm not looking forward to this project on my truck. I had an ATS manifold on my 99'and was pretty happy with it. Luckily I didnt have to deal with ATS directly, I didnt know that thier service was that bad ... ... ... I will put another of thier manifolds on my 06' in the not to distant future. I know another guy here in the Elko area that has had cracks in his OEM manifold on a newer truck.

 

[Cattletrkr]

Thanks TWest. Looks like I was close on my order, I went counter-clockwise instead.

 

[Cattletrkr]

Just thought I'd give ya'all an update. I can now hit 40-41psi boost like I could before. Man that was a long time ago. I'll bet that inside crack had been there for at least a year.

If you look at the last pic I posted you can sorta see the lack of webbing that I mentioned earlier in the thread.

 

[JHardwick]

I can now hit 40-41psi boost like I could before.

Do you think you were losing drive pressure then?

 

[Cattletrkr]

Do you think you were losing drive pressure then?


You can't build drive pressure with a cracked exhaust manifold on a turbo diesel...


I just don't see how you can build drive pressure with a craqcked manifold.

... and three weeks ago I posted:

I can still hit 37psi boost pretty easily. I'm sure it's taking more fuel to get it there though. I mentioned before if I didn't have the exhaust brake I wouldn't have caught the crack. BTW I used to be able to hit 40-41psi, but that was a long time ago. I wonder if this thing has been cracked for a while and it finally got bad enough for me to hear.

I wasn't arguing with you that I wasn't losing boost. I was simply stating that there wasn't enough of a loss in a short period of time for me to think there was a problem with the manifold until I heard the leak.

 

[steved]

How much did that new manifold set you back (if you don't mind me asking?)??



128k on mine... it still looks pretty good, at least the parts your can see.



steved

 

[Cattletrkr]

About $180 plus gaskets which were kinda spendy, $10 x 6 IIRC.

 

[JHardwick]

I wasn't arguing with you that I wasn't losing boost. I was simply stating that there wasn't enough of a loss in a short period of time for me to think there was a problem with the manifold until I heard the leak.

And I'm just asking if you think those seemingly small cracks were enough to lose drive pressure ... ... ... ... . ain't kickin dirt here

 

[steved]

And I'm just asking if you think those seemingly small cracks were enough to lose drive pressure ... ... ... ... . ain't kickin dirt here

My dad's 99's manifold wasn't cracked nearly that bad and it was leaking... caused all sorts of weird symptoms.



steved

 

[KaiHartman]

cummins has an updated one they use now. has gussetts that strengthen where the turbo hangs off of if your still under 100K warranty.

Does anyone know what trucks this applies to? I have a 2005 and would like to get the new design manifold on... I'm only at around 25k on miles.



Thanks in advance!!

 

[Signal73]

Here's the bracing on the engine side:



#ad




And here's the bracing on the outside... passenger side.



#ad

This is the updated one from cummins kai...

 

[KaiHartman]

This is the updated one from cummins kai...

Signal,



The manifold you have was obtained for your 2006 from a dealer? I've gone through the TDR information about the numerous TSB's and other recall data and haven't seen anything applying to MY 2005 trucks like mine... or even the newer trucks like yours. Is there a TSB or is it simply a redesigned manifold that is available to Cummins owners at a cost? I've been trying to decide whether or not to upgrade my exhaust manifold for the past year or so... . it's just that everything adds up $$$$$!



Thanks for the help and the great pics!

 

[Signal73]

My buddy Pauls cracked on his 05 with 88,000 miles and when he brought it to Dodge for warranty that is what they replaced it with. May be a superceeded part # or something.

Pics are from cattletrkr, but its the exact same one.

Thanks,

Jim