exhaust manifold replacement

[rathrbcruisin]

so, got the manifold out. no way that collector bolt was coming out so i ended up cutting it. that broken bolt is being a pain. I welded nuts to it and it kept snapping off the bolt shorter and shorter. So when it got down to the block I broke out the bolt extractor kit. that did not work either. My next plan of attack is drilling it out and putting in a heli-coil. if not for this one bolt, i would be done. hopefully get back at it tonight and just drill it out.

 

[masospaghetti]

I had a 96 Explorer V8 with the internal EGR, came factory with the tubular welded manifolds. Both sides were cracked. I replaced them with the cast iron ones. I doubt the flow difference is significant, if anything the cast one looks like it has bigger ports. The price difference between the cast and welded was enough to make me want to go that route.

The only thing I had to do is modify the bracket that mounts the oil dipstick.

 

[rathrbcruisin]

all done, back on the road and nice and quiet. the dorman manifold bolted up and fit perfectly. I had to end up drilling out that bolt, but was able to get it out and save the threads. I nicked the bottom of the threads a little so they are not as tall as i'd like. I think i'll go back and put a threaded rod into that hole with some high heat thread locker then use a nut. As i was torquing that bolt down it felt like it was just on the verge of stripping. All in all I wouldn't say its a bad job. would have been better if that bolt did not break off After i got it together and went for a test ride it was shaking and missing. I checked all the wires to make sure they werent crossed. finally got a CEL p0302 cylinder 2 misfire. pulled the plug and it looked ok, so i switched it with cylinder 1. then got a P0301 so problem solved...bad plug. fun to drive again.

 

[delexploder]

Speaking of lol, I'll be doing my passenger side manifold tomorrow