Cracked Exhaust Manifold and Broken Studs

[Phantomiz]

Hi,

I have a 2006 37' Holiday Rambler Vacationer W24 8.1L 5 speed Alison Motorhome. For 4 years now I've been plagued with exhaust manifold/broken stud problems. My authorized repair center has repaired this problem multiple times and the last was in June in which many manifold studs were replaced. After a trip to the Outer Banks, I noticed that two more studs were broken. I believe this problem to be poor/incompetent workers performing work on this problem because every time it has had this repair done, other problems have been created. Last time they caused the dip stick tube to bind, a coolant leak and a steering misalignment. All they seem to be doing is replacing parts, without trying to figure out why this problem is occuring (like excessive heat, too much backpressure, warped manifold mating surfaces, exhaust system binding). Anyhow, enough with gripes about my authorized repair center...

My question to all is; What is the best way to once and for all repair this problem with manifold and broken studs? Am I better to try and get this problem resolved by taking it to a heavy duty highway transport facility who works on large rigs or be done with the whole exhaust system and convert to the the Banks system? Anyone have any problems with the Banks system? Broken studs? Cracked headers? Exhaust leaks?

Any help/information would be greatly appreciated...

PhanTomiZ

[Clay L]

Chevy went to stainless steel exhaust manifolds when they designed the 8.1 L and I don't think problems like you are describing are common. I think I would try a different mechanic.

The 454 engine was notorious for having exhaust manifold problems and I had a warped manifold with a broken stud on my 1996 454.
I put the Banks stainless steel headers on my engine and had no issues after that,

[JCM]

Put on Banks headers. Use the same exhaust and intake. Solved my problems and gave me more power in the 50 -80 mph range.

[Phantomiz]

Quote:

Originally Posted by Clay L Chevy went to stainless steel exhaust manifolds when they designed the 8.1 L and I don't think problems like you are describing are common. I think I would try a different mechanic. The 454 engine was notorious for having exhaust manifold problems and I had a warped manifold with a broken stud on my 1996 454. I put the Banks stainless steel headers on my engine and had no issues after that,

Did you install the full Powerpack system or just the torque tube manifold assembly? The Powerpack system looks like it includes everything except for the catalytic converters. Is this something you tackled on your own or did you have them installed? The heat shields on my mufflers are starting to rust off.

[Phantomiz]

Quote:

Originally Posted by JCM Put on Banks headers. Use the same exhaust and intake. Solved my problems and gave me more power in the 50 -80 mph range.

Just the headers? You used the rest of the factory exhaust system?

I will be in need of some new mufflers very soon, so I'm leaning more towards the full Powerpack system...

[Mr JP]

I have just about the same setup that you have 2006 w/5 speed trans on the w-24 chassis. I have the full banks set up (Intake air box & Exhaust system) It was on the MH when i purchased it. The only part I suggest different would be to have the exhaust exit on the passenger side. On mine down the driver side has allot of brake modules or abs stuff. I have wrapped it all with heat blanket wrap. I also just installed the ultra power also and have only run 1 tank of fuel so can not comment on that yet. I would get rid of the factory manifolds and install the banks set-up they do have heat Shields on them also. Good luck JP

[Phantomiz]

Quote:

Originally Posted by Mr JP I have just about the same setup that you have 2006 w/5 speed trans on the w-24 chassis. I have the full banks set up (Intake air box & Exhaust system) It was on the MH when i purchased it. The only part I suggest different would be to have the exhaust exit on the passenger side. On mine down the driver side has allot of brake modules or abs stuff. I have wrapped it all with heat blanket wrap. I also just installed the ultra power also and have only run 1 tank of fuel so can not comment on that yet. I would get rid of the factory manifolds and install the banks set-up they do have heat Shields on them also. Good luck JP

I now have true dual exhaust. Going to the Banks system goes from dual to one muffler back out dual tailpipe. Muffler must be two separate mufflers wrapped up into one. Do you mean install the muffler on the passenger side?

Those modules you speak of are also on the driver's side on my unit.

Let me know how the ultra power works for you...

PhanTomiZ

BTW: Any problems at all with your Banks system? Broken studs, excess heat, burning wires, cracked tubes, exhaust leaks?

[Mr JP]

The modules are on the drivers side along with the brake lines. The banks go into a single muffler the out with a 3" exhaust pipe. I have not had any problem with broken bolts or pipes or any other parts. The headers do keep the dog house area cooler. Workhorse did offer a SS model that banks style headers. I am only getting 6.5 -7.0 on mileage which I am hoping will improve. Good Luck JP

[NALSO]

Phantomiz.

I have the 454, when purchased it had broken manifold studs, three on the left and one on the right. I changed to the Banks Power Pack and fabricated my own intake, header cooling and water injection systems, to lower the radiator temperature while towing.
Towing I get 8 mpg, solo 10 mpg if I can control my right foot. I love the passing/overtaking power on these long inclines.
This last trip to Arizona we reached outside air temps of 100 deg. F - NO overheating problems, No cracked studs.

Henry

[Clay L]

Quote:

Originally Posted by Phantomiz Did you install the full Powerpack system or just the torque tube manifold assembly? The Powerpack system looks like it includes everything except for the catalytic converters. Is this something you tackled on your own or did you have them installed? The heat shields on my mufflers are starting to rust off.

I had the full system installed. They only had to get the one broken stud out. The rest came out without breaking. The mechanic said I was lucky because often one or more others will break in the removal process.

Note that this was 1996 454 and did not have dual exhaust.

[Phantomiz]

Quote:

Originally Posted by NALSO Phantomiz. I have the 454, when purchased it had broken manifold studs, three on the left and one on the right. I changed to the Banks Power Pack and fabricated my own intake, header cooling and water injection systems, to lower the radiator temperature while towing. Towing I get 8 mpg, solo 10 mpg if I can control my right foot. I love the passing/overtaking power on these long inclines. This last trip to Arizona we reached outside air temps of 100 deg. F - NO overheating problems, No cracked studs. Henry

This is reassuring information. I was explaining this whole Banks exhaust system to my better half tonight. She had a difficulty grasping the idea of manifolds and headers. I did get the message across to her though. It's like this: I shouldn't have to spend $600 to $1200 every time we go on a trip/vacation. Not to mention the time it takes to take it to the dealer and back home four times + $300 worth of gas!!!!

Now my big decision is how far do I go with the Banks system. Do I go with Air intake, headers and Ottomind or do I go one step at a time? I know my mufflers are ready to be replaced very soon, so the system may be the way to go...

How about the Ottomind? I know many have installed the UP with great success. I don't like the idea of having to send my Module away for reprogramming and getting it back a few weeks later. With the Ottomind, it's just a plug in the OBD II plug and minutes later it's all done...

PhanTomiZ

Clay...Did you get the full Monty? With the Ottomind? I guess I'm not really looking for performance as much as fixing this manifold/stud breaking problem...

[Mr JP]

Phantomiz; Call Mike or John at Brazel`s and talk to them about the ottomind and the difference compared to the ultrapower. John at Brazel`s answered all of my questions and sent me a updated ECM then I had to send mine in as a core. Ottomind is a generic mod compared to the ups mod. I will have more of an update after thanksgiving when I go on another trip. On the last trip the ups did have more power on the hills and cruise speed. Good Luck JP

[DriVer]

Quote:

Originally Posted by Phantomiz How about the Ottomind? I know many have installed the UP with great success. I don't like the idea of having to send my Module away for reprogramming and getting it back a few weeks later. With the Ottomind, it's just a plug in the OBDII plug and minutes later it's all done......

Brazel's is a Banks dealer and they run both UP and the Banks equipment on their dynos. There is no comparison. Anything that is worthwhile takes the time that is necessary to implement the plan. If you can go to a UP dealer, there would be no need to send your ECM to Brazels and the install would take all of about 2 hours including the pre qualification of a Pro-Scan.

UP is a custom product and it's not canned like the Banks product.

Closing, it does not take weeks to turn around an UP ECM. These things can be done overnight.

[NALSO]

I agree with DriVer. (yes DriVer for once I agree with you)

I also got my Banks system from Jon at Brazel's, I went for the Power Pack Banks system to make my engine breath. 4" of Ram-Air in and 4" of hot exhaust out.

Since I don't plan to keep this coach for a long time, I did not opt for the chip. My main concern was the broken manifold bolts and the increase in performance, do to a better breathing engine, plus a gas mileage gain to boot. (If you can control your right foot.) Cruise Control Helps!

Henry.