Engine/Transmission (1998.5 - 2002) Tips on Removing Exhaust Manifold

[Joe Mc]

The new 3 piece ATS is slated to arrive today. Any tips on removing the old, emphasis on not snapping bolts during removal.



I was thinking of bringing engine up to operating temp. , throughly soaking with penetrating oil, let soak 15 - 20 mins and repeat 1 time - then try to loosen. 125k on truck.



All comments appreciated.

 

[HoleshotHolset]

FWIW:



I took the exhaust manifold off my '94 (with over 190k on the clock)... with a stone cold engine and no penetrating oil. I didn't have any problems...



The bolts look a lot nastier than they really are... You'll find that underneath that nice coat of oxidation is a pretty healthy looking bolt.



I did use some 'neverseize' on the threads when I put the manifold back on, though...



Matt

 

[Mundgyver]

Just a tip here, when you get your ATS manifold, take the end pieces and stick them in the freezer. Take the center piece and bolt it to the old exhaust manifold you just took off. With the center piece on the old exhaust, warm it up with a propane torch to expand the metal. Get one of the ends that you put in the freezer about 2 hours ago and it should slip right in and then line it up with the old manifold holes. Repeat the procedure for the other side. This is the easiest way I know to get them together, unless of course the good people at ATS sent it pre-assembled.



Good luck, have fun and enjoy.

 

[rblomquist]

No problems getting old one off at all, matter of fact, many of us unscrewed some studs by hand.

 

[JGheen]

I have heard your supposed to remove the stock manifold when the engine is cold. Not sure why, I would think the bolts would be easier to remove with a little bit of heat, but lots of people I have heard do it cold. Obviously soak the hell out of the bolts with penetrating oil and maybe even more once you have broken the bolts loose.

 

[justinp20012500]

Yep he said it...

Originally posted by Mundgyver

Just a tip here, when you get your ATS manifold, take the end pieces and stick them in the freezer. Take the center piece and bolt it to the old exhaust manifold you just took off. With the center piece on the old exhaust, warm it up with a propane torch to expand the metal. Get one of the ends that you put in the freezer about 2 hours ago and it should slip right in and then line it up with the old manifold holes. Repeat the procedure for the other side. This is the easiest way I know to get them together, unless of course the good people at ATS sent it pre-assembled.



Good luck, have fun and enjoy.

I did this and it worked great. But dont forget the antiseize.

 

[Joe Mc]

Thanks for the tips - they all make sense.

 

[Hohn]

KROIL-- LOTS AND LOTS AND LOTS OF KROIL!!



Also no impact tools!



Justin

 

[fox]

A warm manifold can warp. Do it cold.

 

[Partyat33]

No Impact Tools, thats my whole plan !!!

 

[MMiller]

I use a 3/8 impact on mine. The rattling of the impact helps loosen them, I think. Don't use a 1/2 impact. Just my $. 02. The ones on my cummins were much better shape then most of the Cats I work on. I have found that an impact shaken a stuck bolt helps remove them, BUT don't use too much impact for the hardware or it will twist off before shaking loose.



I have had my manifold off twice now, I always use new hardware to install. $12-15 in bolts are cheep insurance to get them out the 2nd time, and have no failures later. I never reuse hardware on a diesel manifold.



Penetrating oil is a good idea. If the bolts don't come easy don't use a long bar on the rachet or the bolt will prolly break. I have also found sometimes with stuck bolts to tighten it a little then it sometimes will back out.



All in all I have had much better luck on the CTD then others I have fought. 3406's and 3306's. Ussally the studs are already broken before I get there.



Michael

 

[juicedcummins]

With your ride being a 99, a couple of the bolts might already be gone. A couple of the others will be loose unless you have taken the time to keep them tight.

 

[jerrethomas]

Originally posted by MMiller

All in all I have had much better luck on the CTD then others I have fought. 3406's and 3306's. Ussally the studs are already broken before I get there.



Michael

i know exactly what you mean. Seen it many times also. plus i believe that the bolts are stainless steel that cat uses. try drilling them out once. what a pain.