Skip to main content ↑ ↓
Topic: Exhaust manifold  (Read 3125 times) previous topic - next topic

Re: Exhaust manifold

Reply #40 –
Got everything disassembled, no broken bolts. Did find the oil line rubbed a hole in the wastegate actuator. I expect that will be fun to find.

Re: Exhaust manifold

Reply #41 –
It looks like steel, could it be welded.

Re: Exhaust manifold

Reply #42 –
Quote from: oldguy –
It looks like steel, could it be welded.

Have not heard of that being successful because of the extreme conditions/heat cycles seen by the exhaust manifold.

Like Bruce, I have done this replacement on a 2003 ISL.  Same break.

Also had to pull, machine and reinstall the exhaust manifold on our Caterpillar engine due to warpage.

Just not that uncommon an issue.  I suspect (no statistics on it) that the rear  engine instead of the front  engine where there is ample air flow adds to the likelihood of failure.

Re: Exhaust manifold

Reply #43 –
I replaced my wastegate actuator years ago because of a bad internal diaphragm. Call Cummins with engine serial number and go from there. Seems to be many sources online.

Re: Exhaust manifold

Reply #44 –
Quote from: Doug W. –
I replaced my wastegate actuator years ago because of a bad internal diaphragm. Call Cummins with engine serial number and go from there. Seems to be many sources online.
Yep, just got to find the right one. This one is set at 1.92 bar or just shy of 29 psi.

Re: Exhaust manifold

Reply #45 –
Quote from: wolfe10 –
Have not heard of that being successful because of the extreme conditions/heat cycles seen by the exhaust manifold.
Welding the cast manifold I agree no joy.  The actuator housing is mild steel and if you keep welding temperature and duration limited its quite repairable, but I still would prefer to replace with a fresh component. My luck 2k miles down the road it fails and your in there doing it again.
Scott

Re: Exhaust manifold

Reply #46 –
Bruce, have you thought about using an epoxy to fix wastegate hole
Johnh

Re: Exhaust manifold

Reply #48 –
Any theories on what would cause the exhaust manifold to break cleanly apart like that?  It's seemingly pretty stout material, so I would think not too easy to snap in half.

Perhaps caused by unequal torque applied to the mounting points, so the manifold is under constant stress.  Add to that the repeated heating and cooling cycles.  I can't see vibration being a factor, cuz the manifold doesn't normally "move around".

Or, is it a flaw in the casting.  I know nothing about metallurgy, so I'm clueless...but also curious.

Google says one theory is the weight of the turbo assembly hanging on the manifold is too much stress?

Also, anybody ever used Kroil?  I'm just filing away pertinent info for possible future projects.

Kroil - Best Penetrating Oil | Kano Laboratories, LLC


Re: Exhaust manifold

Reply #49 –
Used Kroil for years in the oilfield,will try mouse milk next,the reviews state it beats Kroil.

Re: Exhaust manifold

Reply #50 –
And homemade works equally well/better.  50/50 ATF/acetone.

Re: Exhaust manifold

Reply #51 –
Quote from: Chuck & Jeannie –
Any theories on what would cause the exhaust manifold to break cleanly apart like that?  It's seemingly pretty stout material, so I would think not too easy to snap in half.

Perhaps caused by unequal torque applied to the mounting points, so the manifold is under constant stress.  Add to that the repeated heating and cooling cycles.  I can't see vibration being a factor, cuz the manifold doesn't normally "move around".

Or, is it a flaw in the casting.  I know nothing about metallurgy, so I'm clueless...but also curious.

Google says one theory is the weight of the turbo assembly hanging on the manifold is too much stress?

Also, anybody ever used Kroil?  I'm just filing away pertinent info for possible future projects.

Kroil - Best Penetrating Oil | Kano Laboratories, LLC



Cast iron parts just dont have a permanent life unlike ductle iron. Much less production costs and reasonable life make it a good product all in all. Lots of heat cycles and the weak point will always present itself eventually.
Scott

Re: Exhaust manifold

Reply #52 –
Quote from: wolfe10 –
And homemade works equally well/better.  50/50 ATF/acetone.
Once you have worked years around turbo charged exhaust systems you will recognize the benefits of the Mouse Milk. Stupid name , magical product. Best applied while parts are at operating temperature. Cooling effect draws it in even better. Yes it is flammable but less than acetone.
Scott

Amazon.com: Mouse Milk Oil 8 Oz : Grocery & Gourmet Food

Amazon.com: Never-Seez NSBT-16N Silver Pure Nickel Special Anti-Seize...
As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.

Re: Exhaust manifold

Reply #53 –
Gotta love that beer can tech.....I do hope  you drank it before using it!!

Re: Exhaust manifold

Reply #54 –
Got the parts ordered, manifolds 214.00 Cummins wanted 1100.00, bolts spacers and gaskets 190.00, wastegate actuator 141.00 ( holset) part. We'll see how it goes together when it gets here

Re: Exhaust manifold

Reply #55 –
Amazon.com: Never-Seez NSBT-16N Silver Pure Nickel Special Anti-Seize..
For those who have never used this it works really good, the only caveat is when using always wear rubber globes and don't get it on you!
Chris

Re: Exhaust manifold

Reply #56 –
Chris Lang, got it on order?👍

Re: Exhaust manifold

Reply #57 –

Mr. bbeane, What gave the broken exhaust manifold away? A typical exhaust leaking sound?? Thanks for the info. Mike

Re: Exhaust manifold

Reply #58 –
Quote from: Chris m lang –
Amazon.com: Never-Seez NSBT-16N Silver Pure Nickel Special Anti-Seize..
For those who have never used this it works really good, the only caveat is when using always wear rubber globes and don't get it on you!
Chris
I can honestly say there were several co employees that refused to use the nickel anti seize and I got to the point that if I was following up on one of there installations I knew before I ever got started I would be in for a battle. I also made it a point when ever possible to assign them there own prior work. Eventually it made sense to them what a difference it made. One comes apart and one is fused together never to separate till complete failure of the bolt. Chris is correct 100% IMO.
Scott

Re: Exhaust manifold

Reply #59 –
Quote from: zmpm01 –
Mr. bbeane, What gave the broken exhaust manifold away? A typical exhaust leaking sound?? Thanks for the info. Mike
  A couple of things. I do a pretty good check over before startup every travel day noticed a little soot around the turbo thought I had a bad gasket. Once we left all kinds of crazy engine codes, and my Silverleaf indicated lower than normal boost pressure.  So a closer inspection it was kind of hard to see with all the turbo plumbing in the way. I replaced some engine sensors last summer, in 12k mile have no check engine lights. So I'm going to assume that between the broken manifold and the hole in the wastegate actuator it was causing some conflicting signals to the ECM. We'll see when I get things back together.