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Old 10-20-2021, 08:01 AM   #1
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I Joined the cracked manifold club today.

I've read where this is a DIY project but take precautions not to break bolts. For those who have done the replacement yourself what advice do you offer? I'm going to call Cummins today check on getting a replacement manifold, gasket set and bolts. Is there anything else I will need?
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Old 10-20-2021, 08:09 AM   #2
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Soak them, soak them, soak them with a good penetrating oil-- several times over a week or so.


Then, just normal "how do you remove a stubborn bolt/nut".


I have done it twice, once on a Caterpillar, once on a Cummins ISL.


Never broke a bolt/stud.
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Old 10-20-2021, 08:17 AM   #3
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Quote:
Originally Posted by wolfe10 View Post
Soak them, soak them, soak them with a good penetrating oil-- several times over a week or so.


Then, just normal "how do you remove a stubborn bolt/nut".


I have done it twice, once on a Caterpillar, once on a Cummins ISL.


Never broke a bolt/stud.
Thanks Brett, I'll start soaking with PB Blaster today.
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Old 10-20-2021, 08:19 AM   #4
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After you take Wolfe10's advice try and tighten them just enough to make them move before you try to back them out. Once you get them to move keep working the fasteners back and forth a little at a time in each direction. This tends to break up the rust and not jam it up in the threads. A little anti-seize on the fasteners when you put them back together should make the project easier if you ever have to do it again. Good luck.
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Old 10-20-2021, 08:34 AM   #5
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Yup, soak them for a couple days before you try to remove.



I did mine ~6 years ago, I took my time, no big issues other then having to go get parts or tools I dropped. Initially I tried to leave the turbo in place but ended up having to remove it to get it lined back up, would have saved me time in the long run.



From what I've read new manifolds are in short supply, you might have to consider after market.
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Old 10-20-2021, 09:06 AM   #6
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Thanks for advice everyone. Jim you are correct Cummins say's on backorder with ETA not available at this time, they gave me a complete kit quote of 871.36.So now I will start searching for aftermarket anyone used aftermarket manifolds?
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Old 10-20-2021, 09:17 AM   #7
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Highly recommend using Kroil.
https://www.kroil.com/
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Old 10-20-2021, 10:35 AM   #8
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Just had a mobile mechanic friend do mine a few months ago, went pretty well. Broke three studs off in the process. Here's what we did to remove them. I had a BRAND NEW pair of Vice Grips ( Good sharp jaw teeth ) heated each stud with a hand held propane torch, good and hot the clamped on the vice grips, backed right out with no problems. We had the manifold out of the way so we had room to operate. Good luck.

I bought everything OEM from Cummins dealer, new studs, nuts, spacers, gaskets, manifold, turbo studs and nuts and came to about $900. My friend did the swap out in about 6 hours here in my yard under the RV port. I had the carpet covered and the mattress removed from the bed and removed the access panel so he could get to the engine better.
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Old 10-20-2021, 10:39 AM   #9
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If you have trouble getting parts local, try these people. I assume they will ship them to you. Central Diesel 804-275-3900 Richmond Va. Cummins dealer for OEM parts. Who I got my ISC parts from. Will need you engine ser* when you call.
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Old 10-20-2021, 11:32 AM   #10
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I sprayed mine on my old gasser everyday for a week sometimes three or four times a day with a 50/50 mixture of ATF and acetone in a spray bottle. Every bolt came out.
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Old 10-20-2021, 11:57 AM   #11
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Highly recommend using Kroil.
https://www.kroil.com/
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Old 10-20-2021, 11:59 AM   #12
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Tapping with a hammer can be a big help as well to help release rusts grip. Works with non rusted fasteners as well. Not saying to mash bolt heads over , also tapping on castings. Keep soaking. Kano Kriol is tested best OTC penetrating oil. I have loosened bolts and nuts with aid of air blunt chisel for vibration that would have never come apart otherwise.
Have also used 3/8" air impact that's too weak or turned down to break a bigger bolt off, but flexes and vibrates it enough to help loosed up the rust. A couple heating and cooling cycles with mapp gas torch and more penetrating oil works as well. Be careful many spray oils burn easily.
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Old 10-20-2021, 11:59 AM   #13
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Answers in both posts #10 and #11 are excellent choices!


Have used both over the years.
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Old 10-20-2021, 12:02 PM   #14
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If you have trouble getting parts local, try these people. I assume they will ship them to you. Central Diesel 804-275-3900 Richmond Va. Cummins dealer for OEM parts. Who I got my ISC parts from. Will need you engine ser* when you call.
I am having trouble getting parts...Cummins can't even give a ETA as to when they might can get parts. I have called several places and no one has so far been able to locate the parts.. waiting on Central Diesel to call me back.

Thanks to all for taking the time to reply.
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