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Old 12-24-2016, 02:10 PM   #1
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exhaust manifold advice please

my exhaust manifold from a '93 cummins 5.9 has cracked.

i've patched it with an epoxy, but expecting the worst, i've been looking for a replacement manifold.

cummins quickserve indicates the part number to be: cummins 3921704

googling that number i see some used manifolds that look like their correct but nothing new.

there seems to be 2 styles to the exhaust manifold, a center discharge and an offset discharge. my '93 cummins is the offset discharge.

in new manifolds i see a new '93 dodge manifold is the wrong one. it's the center one. the 2003-05 dodge manifolds look right but that's 10 years difference in production dates.

here are some of my wrong year but looks right choices:

aFe Ductile Iron Exhaust Manifold for 03-07 Dodge Cummins 5.9L Diesel 46-40012

http://www.ebay.com/itm/Exhaust-Mani...3D172194412371

so if there any cummins experts on here, i'd sure listen. are they interchangeable?
thanks
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Old 12-24-2016, 08:26 PM   #2
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You can use the newer manifolds with no problem.

12 valve and 24 valve 5.9s had the same exhaust manifold bolt pattern on the head, but the 24 valve had larger exhaust ports. Consequently, putting a 12 valve manifold on a 24 valve motor will create a serious loss in power. Putting a 24 valve manifold on a 12 valve motor however, will create slightly less efficiency due to a difference in port matching, but there won't be any restriction and there isn't enough of a power decrease to tell any difference from the driver's seat.

The 24 valve did go into production in 1989 though, so if you have one of those (chances are slim) the newer Dodge manifold is actually the correct one.

Makes sure the outlet on the manifold is the same as yours before you buy it though. I'm not sure what turbo you have.
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Old 12-24-2016, 09:08 PM   #3
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repair manifold

Many welding shops can weld your manifold. Some small colleges and other schools can repair for a low cost. There is welding rod for cast iron.. Frank
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Old 12-24-2016, 09:38 PM   #4
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thank you.

my turbocharger part # from the quickserve site is : 3802272

looking up the turbo charger number i see it was the part number for '92 and '93 cummins and then again for the 2004, 2005, 2006, 2007 cummins. i think that is going to work. thank you.

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Old 12-24-2016, 10:20 PM   #5
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Quote:
Originally Posted by frank-id View Post
Many welding shops can weld your manifold. Some small colleges and other schools can repair for a low cost. There is welding rod for cast iron.. Frank
very true!

i picked epoxy for the first repair over welding. with the epoxy i didn't have to remove the manifold. if i have to remove it, i'll just replace it. grinding out the epoxy may not leave much manifold left to repair.

my next road trip (skooliepaloza) will give the epoxy a workout enough to see how urgent replacing the manifold is. fingers crossed the epoxy holds.
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Old 12-25-2016, 12:08 AM   #6
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With the right rod (or wire) welding cast iron is not that tricky and as often as not, it can be done in place.

One trick is to do the cutaway grinding with the engine running. Does two things...1. keeps any dust or shavings out of the motor, and...2. preheats the metal.

Then too, there is always the junkyard for cheap replacement parts.
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Old 12-30-2016, 05:08 PM   #7
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new manifold came today

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Old 12-30-2016, 05:30 PM   #8
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NOT a Cummins, a DT-360, but exhaust manifold related so ill ask here..

what are the caveats to removing and reinstalling a Turbo?

on my carpenter I believe manifold gasket is bad... when I got the bus there were 2 bolts in the manifold missing, i replaced the bolts but i still have a small but annoyimng exhaust leak onkly above 1/2 throttle.. im guessing the gasket got destoryed as those bolts probably slowly worked out and fell off over time before I had the bus..

since my turbo is connected to the manifold it will have to come off to gain access to 2 bolts that are covered by it.

so it looks like theres 2 oil lines to the turbo, a V-band clamp to a down pipe, and the 4 bolts that hold the turbo to the manifold and then the inlet and outlet pipes on the compressor side..

I have the gaskets for the manifold to head, the turbo to manifold and for the oil line..

do you have to do anything special to the turbo before you put it back on? or just bolt it up and start the engine?

im thinking since i and that bus are down here in florida for the winter where its warm but not hot weather makes for a good time to change that and maybe the downpipe since i know the V-band leaks a little as anytime I clean it and put it back on theres soot on the inside of the clamp.

-Christopher
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Old 12-30-2016, 06:00 PM   #9
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i'm all ears. if someone wants to edjumacate me, i'm listening.

my manifold also bolts straight on to the turbo charger. in the picture, the manifold is upside down, those 4 holes align with the turbo. 2 holes are threaded, 2 are not. i assume they bolt from different directions.

i'm not going to remove the turbo unless i break it or see serious wear when its opened up.

i hope its as easy as unbolting the old and putting in the new. if the stars align just right, i'll do it this weekend, otherwise it'll wait until after skooliepalooza.

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Old 12-30-2016, 06:49 PM   #10
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I was goingto go to Skooliepalooza but once dred was oput I kinda lost interest.. I will go to the florida meet-up..

I guess I do have an advantage if I break the DT-360 changing the manifold I'll go to ohio and get the Bluebird lolol.. thus fsar it seems to run good..

-Christopher
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