Hi, I've been searching for information on how to remedy/solve an issue with the exhaust manifolds and their bolts on the 3rd gen trucks. The company I'm with has an '04 1500 quad cab, '05 1500, and an '08 2500 quad cab, and all three have had the same problem of either the exhaust manifolds cracking/breaking, or the bolts that holds them. so far replacements have been done four times this year, and it is becoming frustrating.

Is there any way to deal with this? I did some searching, and so far one suggestion was to upgrade the bolts to a grade 8, but I want to get as much info as possible.....

Any feedback would be greatly appreciated!


Chris

 

Sounds like warped heads possibly... but all three of them? That is odd.

Need to nail down the root cause of the problem before trying to give an answer. Which bolts break? Where do the manifolds crack? Got any pics?

 

Also curious as to what parts have been replaced 4 times so far. Bolts? Manifolds? You also dont mention where you live. Sand, salt and snow wont help.

I had one or two broken bolts (towards the back side of the engine and on the pass side) in my original manifolds. I went to Pacesetter LTs with grade 8 bolts and havent had any issues since

 

And when grade eights fail, if grade eights fail, there are stage 8's.. there are no better..

Grade eights aren't going to do anything better than grade fives... The only differences between the two is shear and snap strength.. stage 8's, however, once torqued, tabbed, and spring clipped flat out can't move..

for the manifolds cracking, I've got nothing.. unless.. :

Stupid lean exhaust is silly hot.. to the point of glowing.. the things aren't designed for that, they are designed to last at an expected temperature.. I'm wondering what kind of fuel you guys are using, and what kind of mods you've done if any, and what type of environment they operate in..

 

^^^ And thats why I added spring washers to my Grade 8s...... $10 total versus $50

I know a lot of guys like Stages 8s but sometimes the name exceeds the quality (or need) and drives price up. Maybe Im lucy but IMO you couldnt convince me to trade mine out

 

Agreed... Some old timers still wire them, which is harder but absolutely fool proof..

The thing is, its warranted when headers are involved.. often times a few millimeters of alignment off in geometry puts strain on the things, and the joints at the collector and the heads gives.. but we're talking manifolds, which is weird..

Unless they're driving those things over crap that is slapping the crossover, or have done mods to otherwise strain them, I wouldn't have a clue why they would all be giving them grief.. the only thing that makes any sense is running them lean, and using common fuel that could be the cause.. alcohol laden fuel will do it.. so will clogged injector baskets.. a clogged evap will lean an engine out, and all of those could be common if the same environment and fuel source is used..

I'm reaching.. but its an interesting problem..

 

Eww...I forgot all about wiring them. Before my time honestly but Ive heard of that. I have checked mine from time to time and never have needed 1/4 turn. But if I had an exh leak I wouldnt hear it unless it was really bad anyway. My exh can be pretty loud

 

Thanks for the feedback so far - I will talk to our machanic and my boss to get specifics on which trucks had what work. We are in Burlington, Ontario......salt has been an issue since these are landscaping trucks (we do weekly washes in winter, including underneath), and I know the '04 had to get a new starter cuz the road salt killed one of the mounting bolts and wires, and it had both manifolds replaced after they cracked (in July, I think)......

...I'll find out more info....

 

....oh, and none of the trucks have had any performance mods, except the '04 which had a K&N air filter last year, but that was changed back to the stock unit in October. All trucks run on regular unleaded here.

 

I'd look at some common maintenance procedure common to the vehicles that may have caused it. It happens that the bolts snap on the Hemi, but it's not real common, more of a very common 4.7 trait and on that motor it's generally confined to the rear two bolts on the drivers' side. Been there, done that on my Jeep with the 4.7.

As for my Hemi, all bolts were fine when I did my headers. I used the black bolts came with my headers and check them when I do my oil changes at 6k miles. I've never needed to tighten any more than a quarter turn. Was going to do the locking bolt thing but was advised not to on an aluminum block as my local performance shop had seen a lot of stripped threads in the block when locking bolts were used...