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Old 06-26-2012, 10:22 AM   #1
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Exhaust Manifold Problems

My '95 Dynasty 300 Cummins has developed 4 broken bolts on the two front cylinders,,, #1 and #2 (?). I plan to pull the manifold with turbo attached and remove turbo on bench. I need to drive moho about 50 miles for the 4th. I don't want to disable it until after the 4th. I plan to "c" clamp the manifold just to reduce vibration and breakage for the short trip. I plan to upgrade the bolts and the old bolts appear to be a grade 5. Could they be that soft or are metric marked differently? Can I upgrade the manifold to a 2 piece? Please, no comments on the clamps! THX
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Old 06-28-2012, 03:48 PM   #2
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I have replaced the manifold gaskets on a 99 ISB and replaced 1/2 of a 2 piece manifold and all the gaskets on our ISC engine, first thing I did on both was spray the studs a couple times a day with PBS Blaster for a few days, all studs and nuts came loose with no twisted off studs. On your broken bolts if they are flush with the head good luck on getting them out but if you have a stub sticking out spray that sucker every time you think about it also the leaking exaust can cut the head or exaust we were lucky on the ISB it cut a grove in the exaust manifold not the head that I was able to reface. I removed the Turbo before removing the manifold on both, I don't see why you could not get a 2 piece manifold probaly the only type avaliable.
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Old 06-28-2012, 10:47 PM   #3
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Rick, for drilling the broken bolts....find yourself..left handed twist drill bits...they are fluted opposite the normal bit. You will run your drill in reverse. The action of drilling then helps turn the broken bolt in a direction of removal. I got mine from Snap On ages ago and they are VERY helpful with broken off bolts. Many times no easy out is needed...the drill bit does all the work
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