New Exhaust Manifold/New Head

[Volunteer]

The mechanics at the Cummins shop here in Seguin, Texas, are just about finished replacing the head and exhaust manifold on my 1996 Cummins B5.9 mechanical.

I had a serious exhaust leak and since I've used these guys before and trust them, I limped here from Aransas Pass where I was on holiday.

I have 105k miles on the engine and the exhaust manifold had warped to the point where it was actually bending the outboard bolts in and they were no longer 90-degrees to the head.

Needless to say, when they removed the manifold, five of the bolts broke off in the head. It went to the shop to be re-worked and they said there were some hairline cracks in the head which may get worse in 50 miles or 50k miles.

Since I'm a full-timer I opted to get a new head from Cummins and that, along with the new exhaust manifold, is what they're putting back together today.

Although I'll pay what they charge (I already know the head is about $1400,) I was just curious if anyone else has had one of these mechanical B5.9 engines re-built to this point and if so, what did you end up paying?

I'm already wondering if I have enough Social Security checks saved up to cover this.

[hillboy]

They should have a pretty good picture of the cost. The new manifold is sort of expensive also. Then there is always the "while we are in there" opportunity. Injector check etc.

Another concern would be what caused the warping and will the replacement parts solve the problem. Knowing the shop is a positive.

[CyberVet65]

Make sure to get the aftermarket exhaust manifold. It is in three pieces and will not warp or bend the head bolts. I had my manifold replaced a 23,000 miles for that same problem. They had to pry the manifold off witha bar. The stock manifold is a single piece.

[Triker56]

A new 2 piece factory manifold cost me on 8/05 $260.56 including tax. No labor included. 5.9L ISB

Stock was 2 piece also.

[J Walker]

With 60,000 miles on my 2000 ISB I haven't had to deal with the exhaust manifold yet, but I read that they shrink and have to be replaced at some time. If I am lucky or don't put too many miles on mine I may escape the replacement. I expect a really big bill if it happens.

[Triker56]

Quote:

With 60,000 miles on my 2000 ISB I haven't had to deal with the exhaust manifold yet

I had to replace mine at 52,980 miles

May your luck hold out.

[RustyJC]

The good news (well, sorta ) is that the 1998.5 - 2002 ISB (24 valve) engine's exhaust manifold is relatively weak and typically cracks before it can do any damage to the head. For those of us with the ISB in Dodge trucks, multi-piece replacements are readily available from companies such as ATS, BD Diesel, etc.

Rusty