8.3 ISC cracked manifold

[NWCycle]

If anyone else out there has any secrets or tips on replacing I have been spraying liquid wrench on the nuts and Bolts for a few days hopefully I will not snap off any bolts,
looking for any help or information if possible I am replacing with 21 Cummings parts
I had watched a couple videos so pretty much know what I’m getting into and he had a quote from a local Cummings facility and they’re looking at around $1200 labor if they do it

[Ray,IN]

Are you referring to the Cummins ISC engine? The older years like mine are known for breaking the exhaust manifold due to the entire weight of the turbocharger and associated piping resting entirely on the exhaust manifold.
The new Cummins replacement manifolds are reinforced and noticeably heavier to prevent breaking the manifold.
I had a HDT repair shop replace mine. I had soaked the bolts with PB Blaster rust penetrant twice a week for a month prior to having the work performed; still 3 bolts broke off in the block.
The technician said he had to work on those broken bolts using a mirror because they were underneath the manifold. That is one of the reasons the total bill was $3,000.


I had entirely removed the bed and framework, covered the carpeting with the sticky carpet protector and made it as easy to work almost standing on one's head as possible. The shop owner said had I not done that the labor bill would have been much higher.

[jacwjames]

I replaced mine myself. Did the same thing, sprayed PB Blaster on the studs fro a couple of days, didn't have any problem getting the studs out.

Initially I tried to leave the turbo in place but finally ended up taking it out to provide more room. Not a bad job other then dropping tools or parts and having to go retrieve. I think I spent ~$650 on parts at the time.

[ziaptrn]

I have had good luck removing the bolts on Cummins exhaust manifolds after spraying/soaking with PB Blaster and then a 50/50 mix of acetone and transmission fluid. A mechanic friend told me about the transmission fluid and acetone. I mixed it and put it in a metal squirt can (old-school oil can style).

The bolts came right out 5 days after alternately soaking with both PB Blaster and the mix.

I've also broken bolts so was quite relieved when they all came out. Can't say for sure that it was the 50/50 mix that made the difference, but it surely didn't hurt. Just a thought.

John

[radar]

Can’t help with the replacement but it happened to us. We had it changed. Wasn’t too bad of a bill. Hope you get it done and get back on the road quick.

Cheers.

[Bruce Anthon]

I did this job myself last year on my 2003 ISL with 60,000 miles on it. Soaked the bolts with PB blaster for 6 days. Our local CAT dealer had me speak with their lead mechanic before I started the work. He explained the trick for them is not to use an air gun to break them free. He recommended a long breaker bar and then tighten the bolt ever so slightly before backing it off. I did mine that way. You will feel it move slightly as you start to tighten the bolt. Then reverse the direction. After doing it I saw other posts and tube videos that mentioned the same process. It is also a good time to replace the oil feed line to the turbo. I changed the thermostat and coolant also. Good luck and let us know how it went for you.

[NHRA225]

Did Mine way back in 04- Cracked Manifold --I replaced with a new Design from Cummins has more webbing in the cast for added strength . Soak -Soak and re Soak- Please do not use an Air impact -Long Breaker bar with slow turns all the way out- Going back on I used Cummins S/Steel bolts with a High Heat Anti Seize- New Turbo Base Gasket and Cometic Gaskets on the Manifold. Took me 2 days to Finish it up.

[ASU777]

$1200 is a steal. My Cummins shop quoted me $4000.


If you are concerned about breaking bolts, you can use an induction heater on them. It's pricey. $500 for the tool vs $4000 in labor.



Induction Innovations Mini-Ductor II on Amazon.



For me, it was a gamble on reducing the risk of breaking a bolt. I didn't have any experience recovering from this situation and did not want to learn on my motorhome. I have to say the tool worked really well.

[NWCycle]

So far so good, The $1200 was labor only, Going to try and do myself as I am a pretty good wrench, but out of my league working upside down...
I have been using the trans fluid mix and Liquid wrench to soak, I tried the EZ ones on top so those came out with the tighten and loosen trick so far..
Will get the the others but when commuted need to remove all turbo crap
Stay tuned !!!!


And Thank you !!

[NWCycle]

Update,
All boots came out with ease, did the tighten and loosen trick, I used a hair dye bottle to mix the acetone/Trans fluid and works awesome, and has the measurements on side I made 50/50 @8 oz.
So off to order all the parts and will update

[NWCycle]

Now all bolts are loose, Went to order up OEM parts...
National back order 3 months minimum....
Do I dare try the China crap?
I can get everything else from Cummins, I am also doing the oil hose and misc gaskets around turbo...
Any thoughts ? all welcome Thank you

[jacwjames]

I wouldn't be afraid of an after market manifold. I have not doubt that the one Cummins sells is probably made there.

Do some checking, some of the aftermarket have additional support/fins cast into the manifold.





Back in ~1998 we bought a new Class C on a Ford Chassis. Within 8 months the passenger side manifold cracked and it took Ford ~4 months to repair because there were none in stock. I asked for an extension of warranty since we lost use of the rig but was denied. After we got it back we couldn't take a trip right of way as I was out of town, but when we did guess what, the drivers side manifold failed. So I installed an after market manifold. Soon after that the passenger side failed again, it warped, so I just had it machined flat and reinstalled it. The drivers side is still in good shape.

[NWCycle]

Pretty much choice, but with the amount of thread grease this will have, should be no issue again if it breaks.....
Thank you