Well, title says it all, one problem after another. Took the truck to the shop to get that ticking of an exhaust leak taken care of. But we find out quick thet the hole isnt in the crossover, its in the passenger manifold about an inch above the flange. Now for those of you that dont know my truck is the rustiest thing on four wheels out there. The bolts will be a bear to get out. Rotted to nothing.. I am looking at these two things on ebay from the same guy, one has both manifolds, and the other has one. But for the same manifold in the pics there is a different casting number. In the one listing he says gm parts, the other not what do you guys think i should do??? I eally need to do the injectors and plugs bad, should i wait?? Will driving it with a hole the size of a pen hurt the engine? I wanted to jb weld it but expand and contract will occur and the weld will fall out?? This is why i cant pay for plugs and injector because of the same old crap breaking.... Sorry super frustrated, almost bought new rims today too. Felt like a jerk, because i had to back out of that one....
Here are the links, please let me know if they dont work..
http://cgi.ebay.com/ebaymotors/6-5-DIESEL-NEW-EXHAUST-MANIFOLDS_W0QQcmdZViewItemQQitemZ250330947109QQptZ MotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/6-5-RIGHT-DIESEL-EXHAUST-MANIFOLD_W0QQcmdZViewItemQQitemZ350156591017QQptZM otorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

Here is a used set:
http://cgi.ebay.com/ebaymotors/6-5-DIESEL-TURBO-EXHAUST-MANIFOLDS-IN-GREAT-SHAPE_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c66Q3 a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318Q7c301Q3a1Q7c293 Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec0Q2em14QQhashZit em330305498215QQitemZ330305498215QQptZMotorsQ5fCar Q5fTruckQ5fPartsQ5fAccessories

How accessible is this hole? If you can, instead of replacing the manifold, why don't you drill the hole out bigger, to the size of a common pipe plug, and plug it. Put some red thread locker on it if your really paranoid about it coming loose.

Manifold is totally crusty, it will fall apart....

What about a rivet, I know that there are a bunch of different types of rivets that you can get. Can't remember the name, but one type, when "popped" creates a large flat surface on the back. I'll have to look it up, give me a minute.

Okay, this site has dimensions for LSR rivets (http://www.crawfordproducts.com/lsr.htm) (Load Spreading Rivets) shouldn't pull through or blow out your manifold hole. As you can see they can cover pretty big holes.

jb weld won't take high heat

Manifold is totally crusty, it will fall apart....
SO so :sorrysign

that sucks man i went threw the same problem on a 1994 6.5 turbo and and all the bolts broke off in the head and i had to drill them all out. good luck

Yeah,they are just really bad...... I like your thinking inline, but i want a permanent fix. Im going to have a shop do it because of the bolts breaking, im sure they will have to drill and tap EVERY SINGLE ONE, the shafts of the first bolt you can see is all flaked, so does the single pass. side manifold from ebay look like my best bet, the drivers side manifold is in a lot better shape.

Maybe when you get the manifold replaced, you could take a picture of the old one. I've never seen a cast iron part like that rust through, so I'm curious.

I would go with the single passenger side manifold, if your driver's side is in good shape, shipping should be a little cheaper that way too.

I will take a lot of pics when it gets replaced. I will buy the new one sometime tonight...

:bawl::bleah:

Ouch, that really sucks man. We should really just get you a giant vat of PB blaster that you can dip your whole truck in.

On one of my boat engines,theres a tuned cast iron pipe comming off the turbo.Theres a 3/4 inch plug in the side of it.One day when i fired the motor up the plug blew out.I cleaned it with a wire wheel and glued it in with JB weld.This pipe gets hot,well over 250 degrees.I have cooked steaks wrapped up in tinfoil on this pipe.It has been holding now for 3 years.

:funnypost

put a pipe plug in it. What you got to loose?

put a pipe plug in it. What you got to loose?

Maybe the plug will outlast the rusted out frame. :wtf: you got to lose?

Sad part is, its got the nicest frame out of all the vehicles i have owned!! Look in my garage, my tahoe, and gasser rado. Oh and forgot to add i put a new rear diff cover on, so the rear axel looks nice!!

I am just finishing my exaust manifold on the pass side 11 hrs in and just compleating it. Two days of heating up the bolts just to back them out. Got all but one the last one of course. the last one the stud broke off about a 1/4 out of the block just enough to weld a nut on the end and heat and back out. Got my manifold off of ebay, different casting numbers because the orginal bolts are 3 bolts and 5 studs on the manifold and the new one are all 8 studs no smaller bolts, learned the hard way. But got my new gm manifold for $85 from ebay good deal.

Ok maby its not to commen but why dont you have it welded? Hell if you come here I'll weld it for you. probally wolnt even have to take it off of the truck just take the inner fender out (depending on where the leak is). If you have a welder you can get both stick style rods and also mig style gas that will weld cast iron. Ive welded a exaust manifold on one of the vans at work after the split opened up a 1/4" hole. So any way my offer stands, for any one for that matter. Cast is easy to weld if you have the right stuff you just have to prep it right to get it to hold.

Justin

I was going to suggest welding it (as I do a lot of things), but then thought about the sparks falling down in the manifold, and if you take it off to weld it, you might as well replace it.

if its just cracked i wouldnt worrie about the sparks they will just blow out the exaust. If you were really concerned you could unbolt the crossover and run the truck to blow them out with out having them pass through the turbo. Now if there is a hole that you are filling then I would consider taking the cross over off but like I said before if it was mine I wouldnt worrie about it if its just a crack.

Justin

Thank you for your offer dracor!! I am going to get my brush guard fitted this weekend by a good welder and he says he has welded cast iron before. Im going to have him give it a try. I want to make this motor last till i find another. I really dont want to take the crossover off because it took the shop forever to put it on, it is a warpspeed but i guess it was stretched out just a little to far to bolt diretly to the flanges. So i was told it was a bear to install. The hole is about the size of a pen stick. I will let you all know how it goes, should be done saturday..