Engine/Transmission (1994 - 1998) Exhaust Manifold Leak

[GJolicoeur]

I found an exhaust leak at the middle of the front (#1) exhaust flange. Will it be simple enough to remove the bolts and install all new exhaust gaskets without removing the turbo, etc. ?



I was wondering if part of the reason for the development of this leak was because the manifold has shrunk, and if I might have leaking problems with new gaskets anyway? Anyone have some experience to share with that one?



When the truck is cold (first start in the AM), it misses - not at idle - but when I pull away - especially if I pull away in first gear. This goes away after a few minutes of running. I noticed today that when I revved the engine while the hood was open, I saw puffs of blue smoke and carbon squirt out of the manifold in the center of the gasket when the truck was missing.



Is it possible the two issues are related?



Will I be able to get gaskets from the Cummins dealer or is it strictly a Dodge part?



Thanks for any and all advice!



Greg

 

[Cooker]

An exhaust leak will affect you performance. It will also make your truck sound louder. You can removed the manifold bolts for the 1st, 2nd, and maybe 3rd cylinders to squeeze a new exhaust gasket in there, with a little help form a pry bar



I would think that it is likely the leak has resulted from the manifold shrinking.



Cummins and Dodge both have the gaskets and believe it or not that is one thing they are pretty close in price on. The sell for less than $3 each at both places around here.

 

[GJolicoeur]

Yikes! - use a pry bar?? Wouldn't it be a good idea to replace all of the gaskets? It doesn't look like a tough job. I put a wrench on the front bolts and I was able to move them without much difficulty,...

 

[SmokinU]

GJolicoeur,



I have an exhaust leak in the exact same spot as you. If you rev the throttle, you can see the soot fly out of the leak. If you get around to fixing it, let me know how easy it was to do.



Brandon

 

[chrleb1]

If the gaskets look like that they have pushed out of the manifold and it is a stock manifold, chances are that it is shrinking. I would not suggest that you pull the whole manifold off. When they shrink they are extreme a PITA to get back on. Also when they shrink, they sometimes bend the bolts. It is possible to change just one gasket. Take the bolts out of the one you want changed, then loosen the rest around that cylinder.

 

[illflem]

I replaced a stock manifold whose bolts were badly bent with an ATS recently. What amazed me was that after the bent bolts were loosened they went straight. I think all you need to do is loosen all the bolts, replace the gaskets and retighten.

If it was me I'd replace all of the gaskets.

 

[SMorneau]

My bolts stayed bent. I would drop the $$$ for the ATS.



If I used a pry bar I would use it very very carefully If you take the stock one off be ready to open up some holes before you put it back on.

 

[GJolicoeur]

Hello BPeiffer;

I changed out all six gaskets today - took about 3 hours tools out to tools back. All the bolts came out without much difficulty - although it took some ingenuity to get at them all. The new gaskets have a raised center that crushes when the bolts are tightened.

The manifold came away without effort and didn't go anywhere - very convenient. I slipped the gaskets in and put the top bolts in to hold them and started them on a few threads until all were in.

Don't forget to follow the tightening sequence (start in the center and work out).

Check the link here to see the picture of the old ones - notice the stretching on a couple,...

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[SmokinU]

GJolicoeur,



Thanks for the informative post. I decided to replace the gaskets when I install my pyrometer. The bad gasket looks like the top left one in the picture you took. Did you separate the manifold from the turbo, and how much did the gaskets cost you? I need to replace it soon, because it is making a sooty mess inside my engine compartment.



Brandon

 

[GJolicoeur]

I didn't have to separate the turbo from the exhaust manifold - thank God! It looks like a tough job. I just took off the 12 bolts and it came right away from the engine about 1/2 inch. Perfect for getting the job done.

I paid about $3. 50 each for them at the dealer.

Good luck!