Buy specialty tools and you'll never need them.

I bought the OTC 6005 glow plug removal tool before changing my plugs so I wouldn't get slowed down by any swollen plugs.

Of course today, I pulled the plugs with no problems at all :rolleyes:

So the nifty new tool goes back in the box.

Thats the way it usually goes....LOL.:)I'm glad though you got them out with no problems.Excellent job.

Thats the way it usually goes....LOL.:)I'm glad though you got them out with no problems.Excellent job.

Thanks :) After changing out the lift pump and adapter plate, I was ready for another dirty and PIA job. I was happily surprised.

Hopefully pulling the manifold will be as easy (ha ha)

Sure, those manifolds usually pop right off... :rolleyes:

This tool made it an easy job, it's good that you bought it. It's the same as with umbrellas and spare tires, you only need them when you don't have them.

Maybe get a torch for the manifold _before_ you try? :)

Maybe get a torch for the manifold _before_ you try? :)

LOL, yes that should do it :)

Well I soaked all the bolts with liquid wrench for about a week and the first two long ones (that hold the intake tube bracket) came right out. Also the nuts for the exhaust came right off and are good enough to reuse so I'm hopeful that I won't need anything more than a couple well placed whacks with a 2x4 if t doesn't come right loose.

Is it possible to replace the bolts that hold the exhaust manifold to the engine? If it is, I'd do that ... Mine look so rusted that they'd probably brake off if I tried to get the nuts off. I'm still wondering if Hummer headers would fit, might be a nice upgrade if I need a new exhaust at some time ...

Is it possible to replace the bolts that hold the exhaust manifold to the engine? If it is, I'd do that ... Mine look so rusted that they'd probably brake off if I tried to get the nuts off. I'm still wondering if Hummer headers would fit, might be a nice upgrade if I need a new exhaust at some time ...

If I can't find them, there's a local place where I can get some made if I need to.

I'm assuming that the Banks manifold is matched to the stock one on the driver's side and that the 3" exhaust is tuned for both of them so I'm going to stick to the book for now. Headers would probably fit with a little work. Pitfalls I see are AC lines, AC compressor mounting bracket for sure. Clearance would be tight past the frame.

you have to be kidding,failsafe=sledgehammer or a duramax:eek:

I'm assuming that the Banks manifold is matched to the stock one on the driver's side and that the 3" exhaust is tuned for both of them so I'm going to stick to the book for now.


Yeah, I was thinking of the Hummer headers that were on the 6.2s which didn't have a turbo. You'll need the headers that fit for the turbo. I guess they are included in the kit?


Headers would probably fit with a little work. Pitfalls I see are AC lines, AC compressor mounting bracket for sure. Clearance would be tight past the frame.

The question is how much work? I know someone here did it on a van and had to modify the headers, but vans are tight. It's not something I could (reasonably) do myself, so if I need a new exhaust, I'd eventually have to go to an exhaust shop and have them make something. That would be the time to switch headers, but there may be too much work involved. If the A/C compressor bracket is in the way, that would be quite a problem already ...

It is possible to replace the manifold studs (although I thought these had bolts, which are obviously replaceable). Problem is, when you go removing those studs many of them break off, which means lots of time with a drill and an easy out. I've done a few exhaust manifolds and they're not much fun.

The fun ones are the Fords with the newer aluminum Triton engines - they'll come in with an exhaust leak and they'll have broken studs when they come in. Something about the design, for whatever reason they break off by themselves and then the exhaust leaks. Then you go to take the rest of them off and they break too (although I figured out you can get them out without breaking them, it just takes careful use of an air hammer and a special socket). Of course they're impossible to get to as well - I put them up on a hoist and take the wheelwell out, and sometimes you have to jack the engine up out of its mounts. Then you have to drill and easy out all of them without breaking anything or ruining the head, and replace all of them... Last one of those I did was estimated and billed at 5 hrs. labor to fix two broken studs causing an exhaust leak, so $350 in labor alone... I got it done in 3 hours though... Still, makes one of these 6.2s look like a piece of cake.

Yeah, I was thinking of the Hummer headers that were on the 6.2s which didn't have a turbo. You'll need the headers that fit for the turbo. I guess they are included in the kit?


One manifold is included in the kit. It's a cast iron unit with an outlet to the turbo on top and to the front. I retain the stock manifold on the driver's side.
http://www.dieselplace.com/forum/garageimage.php?do=full&p=73864&d=1221752911
http://www.dieselplace.com/forum/garageimage.php?do=full&p=73418&d=1221200682http://www.dieselplace.com/forum/garageimage.php?do=full&p=73419&d=1221200688http://www.dieselplace.com/forum/garageimage.php?do=full&p=73421&d=1221200701http://www.dieselplace.com/forum/garageimage.php?do=full&p=73422&d=1221200708http://www.dieselplace.com/forum/garageimage.php?do=full&p=73423&d=1221200718http://www.dieselplace.com/forum/garageimage.php?do=full&p=73424&d=1221200727
http://www.dieselplace.com/forum/garage.php?do=view&g=12965#

Of course they're impossible to get to as well - I put them up on a hoist and take the wheelwell out, and sometimes you have to jack the engine up out of its mounts.

I think they will come out OK, I'll be working on that step this afternoon so I'll let y'all know. The two long stud-end bolts came right out with a little soaking with liquid wrench. I removed those to get the air intake bracket off. Problem is, that one of the studs on those bolts is so long it nearly touches the frame and I can't get the bracket to slide off the end. I might just trim that stud off and replace it if it's needed for something with the turbo kit.

Yeah, the 6.2s are easy... I was referencing the Ford motors there. I think you should be able to rock the engine around on its mounts and get that bracket off by the way...

Yeah, the 6.2s are easy... I was referencing the Ford motors there. I think you should be able to rock the engine around on its mounts and get that bracket off by the way...

High Sierra, I owe you a beer. I never thought about rocking the engine against the mount. Strategic placement of a crowbar and I was able to slide that bracket right off.

As far as getting the bolts off, I wasn't able to get enough leverage to loosen them up and my breaker bar and a socket didn't have enough clearance to get on the bolts. I ended up clamping a closed end wrench to the breaker bar with hose clamps and that worked just fine.

I have new injectors on the way so i think I will pull the old ones before bolting up the new manifold just because that will give me loads of clearance to work with.

failsafe way to avoid problems is to not drive/use your truck. It'll never give you problems then! lol