Engine/Transmission (1998.5 - 2002) Lost Exhaust Manifold Bolt

[KevinSmith]

I thought I had either a turbo going out or a boost leak. Often I hear a noise while under load that seemed to be associated with the turbo. While looking for the boost leak I noticed the exhaust manifold was missing the bolt nearest the firewall. I think this explains the noise issue but has any one else had this happen? I haven't been able to see if the bolt broke or if it rattled out. Does any body know the bolt size and grade, and the proper torque.

 

[dresslered]

Don't have the specifics on the bolt size here at work, but there is a TSP that covers the 2001 for this problem. The dealer basically puts a little metal tab between a pair of bolts that prevents them from vibrating loose. When I first noticed the problem, I had a couple of bolts hanging by the last threads. Good luck.



Update:



PERFORM TSB 09-002-01

parts: 4 ea 5072387-AA



Exhaust manifold bolt retention straps.

This bulletin applies to vehicles equipped with a 24-valve diesel engine built on or between engine serial number 56419738 and 56777585, with a date of engine manufacture from January 01, 1998 to September 22, 2000. This information is available on the engine data plate, which is located on the left side of the engine, affixed to the side of the timing gear housing.



Vehicles that are used for extended heavy trailer hauling purposes may experience a loss of exhaust manifold bolt torque. This condition may lead to exhaust gas blow-by past the exhaust manifold gasket(s) and even loss of exhaust manifold bolts.



A new exhaust manifold bolt retention strap has been released as a means of locking the outboard exhaust manifold bolts in place. This will prevent bolt rotation and torque loss during the thermal expansion and contraction cycles of the exhaust manifold.

 

[bnbrown]

On our 2000 have lost that bolt twice now (currently MIA)... bought a whole set of new bolts (used, but new to me). I tried to get the bolt from the cummins dealer, but they were always out of them so I just got the whole set from a dismantler. I would just send you one but I forgot them at my folks' place in San Diego... so have to get them to send them out to me yet... my dads '01 and friends '02 have the straps on them and seem to work, oddly though my '99 gets worked a heck of a lot harder and has never lost a bolt.
Have a nice black crecent on the silver heat blanket on the firewall from the exhaust blowing by.

 

[klcammie]

Just found one bolt missing and one loose. Got New ones from Dodge dealer, but need to know torque. Thanks for the info about retention strap I will get one.

 

[DavidC]

32 ft. lbs



Dave

 

[JAlford]

Another option is to use safety-wire like on aircraft bolts. My exhaust manifold bolts came loose a few times when the truck was stock, I installed safety wire when I replaced stock manifold with ATS Pulse, and no problem since in 7 yrs.

Jeff

 

[Midnite]

Jeff, could you post a pic of your safety-wired bolts? I can't visualize how that would work.

I've checked mine a couple of times over the years and they don't seem to have loosened, but it would be nice to safety wire them just for the peace of mind.

 

[gathomas]

Another option is "Belleville Washers" you can educate yourself here:
Disc Springs, Belleville Springs & Washers by Key Bellevilles, Inc.

 

[JAlford]

Jeff, could you post a pic of your safety-wired bolts? I can't visualize how that would work.

I will post pics in a few weeks when I get back if I can remember, truck is sitting in the airport parking lot and I am 800 miles away on a jobsite.

Jeff