Is there anyway to repair/weld a cracked exhaust manifold? This is off an Escort Cossie. What options do I have? Photo is taken looking into the hole where the turbo bolts on.

Cheers
John
[/IMG]http://img6.photobucket.com/albums/v20/JohnP007/Garage/Cracked_Manifold.jpg[/IMG]

 

u could drill each end of the crack witha small drill, grind out the back of the crack - get the manifold really hot (like in an oven) and weld it all back up using a cast iron rod (they do exist) and then back in the oven and let it cool down slowly of its own accord (with the oven switch off) . this should stabilise any expension/contraction causing the weld to crack prematurely.

some more info here : http://www.twi.co.uk/j32k/protected/band_3/jk25.html

 

you need to take the / out of the first [img] mate!

 

On behalf on John P

 

Thanks for the info. A bit out of my league, so will be taking it to an engineering shop so they can have a look at it.

Cheers
John

 

they all go there mate,that one doesnt look too bad,ive seen a few with 3 or 4 cracks in them, mines the same,was going to buy a brand new one but was told it would be just the same within a few weeks!

 

mine is gone in the exact same place but it gone through to the other side aswell any idea how much a new manifold is

 

same story from me - very common place for a crack - just as you've shown...
is the crack obviously going through to the outside underneath?
IMO, don't worry about it..

 

is this only apply to escos or is it 4x4 saph aswell.


im had both and not had this probelm - am i lucky or could it be cracked and i doent even know?

 

4x4 as well Dave - i gather a lot are cracked in a similar fashion without you knowing - if you never take it apart, you're unlikely to know - the crack often doesn't go all the way through the casting, even if it does it often doesn't 'leak'.
Similar to turbo exhaust housings - cracks are common and often unnoticed.

 

PHEW

 

Hmmm, might look into getting one of these>>>> Supersprint part number 823201

 

Just got a price on the above manifold £898.00 including VAT

So, can I run the manifold with the crack? It doesn't appear to be all the way through? I might just chance it.

Cheers
John

 

yes John, use it, nothing to loose.. it's probably been like that for ages.

 

You found the cause of the crack yet? on 2wd its pften the failure of the turbo damper/mal adjusted, but the 4wd doesnt have one, any ideas?

 

on the 4wd manifold it is just a thermal stress crack in that position.

 

thought while the head was off today id have a look and whip the turbo off - guess what.....



doh!

 

I was at GGR the other day and the turbo was off one of the Escort Cossie's, so I had a look, and guess what, that was cracked as well, in the same place.