it looks like its time to start shopping..
looks like mine in cracking more and more..

should I just get a cheap replacement from RockAuto(~$150 or so)...or
a 3 piece unit..(~$470)??
I'm not planning on twins any time..
I have 70HP injectors..no chip..no tuner..
stock hx35 turbo..until it dies..then I might a little larger.

are they really hard to get out? I'm more concerned about the studs that go into the head breaking than having to cut off rusted nuts.

thoughts?

-dkenny

 

I can't offer much advice on a new manifold (mine is still stock). But as far as removing one, at least one week before you plan on taking yours off, start spraying all the fittings with a good penetrating fluid. PB Blaster and Kroil are two good ones to use. It'll make the job way easier.

I used that same trick on my fuel tank straps when I had to drop the tank (fuel sensor), and the I did not have to fight the bolts at all.

 

I got the old manifold out..

it was time to replace it..
the one photo is the bottom side of the manifold..the crack wraps around to the top side..



the other photo is the one stud the broke..the bottom on #6
should I try to get the rest out or just shim the new bolt so it doesn't hit
the remains of the old one?




-dkenny

 

Jeez, that looks like its been at the bottom of the sea for awhile!!!

I always figure those bolts are that long for a reason, but if you only broke one you are way ahead of the game. If you are going aftermarket 3-piece I would figure a shorter bolt would be ok since you have the expansion/contraction joint. If stock, I may would want to get it out...#6 I think would be limited access.

I'd soak it as sug't above and find a piece of copper tubing that you could slide in the bolt hole to center a bit and then patiently coax it out of there if you go that route.

Good luck!

 

thanks for the info..
i hadn't thought about using a piece of copper tubing..

I got a better look today..it didn't break down inside..but right at the surface of the head..darn..now it has to come out..

I went with the cheaper one piece from Rock Auto..best choice..not likely. but the other place didn't back to me to order and the model I selected is discontinued...

now to go spend the next couple of hours working on it..

-dkenny

 

Maybe chase the holes with a tap and dip the bolts in anti-sieze too...

 

yep..cleaned all the holes and threads..
I couldn't get one stud out of the turbo..so it stayed..
anti-seeze on everything...used lots..

ended up by drilling and tapping the bottom hole on #6...I must have gotten lucky..it all went back together..

then I found out I cracked the turbo oil drain pipe..
I got the bolts off..didn't break them..thankfully..
I've search but cannot find a replacement...I can find the turbo end and hoses but not to metal pipe..I found a flange that can be welded to a pipe from a place I won't order from..so it JB welding at the moment.I hope it works..

hopefully the new manifold lasts a long time..
-dkenny

 

It's always sumthin', huh?