quick question about leaking exhaust manifolds - Diesel Forum

jchadw · 08-20-2006, 05:39 PM

I have an 06 PSD and I was underneath installing a Mag Hytec rear diff cover and decided to take a look to see if I could find out why when I have the air conditioner on I smell exhaust blowing through the vents. On both exhaust manifolds at almost every exhaust port I have black soot around the manifolds. I would not think that this would be acceptable. From what I can see there are no exhaust manifold gaskets on this motor. Am I correct? I do have a Banks 4" turbo back exhaust but I don't think that this would cause the problem as the manifolds have a flexible coupling between them and the turbo. Because of the aftermarket exhaust is this something that you think I will need to pay for or should it be covered under warranty? Last question, what would the fix be for this?

Thanks in advance,
Chad

GrampyJim · 08-20-2006, 06:47 PM

A little bit of soot around the manifolds is considered normal for these engines.... Exhaust manifold gaskets are available if it considered necessary by your dealer.

jchadw · 08-20-2006, 07:09 PM

Thanks for the response. Are the gaskets difficult to install if I were interested in doing myself? The driver's side doesn't look so bad but the passenger's side looks like kind of a pain to do. Any tricks?

ford_doctor · 08-20-2006, 07:31 PM

The gaskets aren't too bad to do but remember I have a hoist and everything I need. I find it is easiest to remove the front wheels and then the fender wells. With those out of the way there is more than adequate room to work in. No need to remove the y-pipe bolts. Just remove the manifold to cylinder head bolts, slide the gasket into place, install and torque the bolts.

Installing the gaskets does effectively fix minor leaks at the manifold. I have made many a customer with complaints similar to yours happy by installing the gaskets.

jchadw · 08-21-2006, 04:35 PM

Stopped by the dealership at lunch and now I have another question. The tech came out and looked at my truck and said that usually it is just one or two cylinders that leak and that it was strange that all of mine were leaking. He said that until they heat up and expand most all PSD's will leak at cylinder or two. When I mentioned to him that I thought there might be a gasket kit out there to remedy the situation both him and the service writer said they had never heard of them. Does anybody know a part number for this kit?

ford_doctor · 08-21-2006, 07:51 PM

All they need to do to become informed is to run an OASIS report and select Symptom codes for "engine/exhaust system" to find it. This is something EVERY TECHNICIAN is supposed to do on each job with concerns.

The TSB # is 05-13-09

The Part # is 5C4Z-9448-A

Find a dealer that knows how to do their job!

GrampyJim · 08-21-2006, 10:13 PM

Utterly amazing that some techs wont use the resources offered to them... I am led to believe that many dealers don't put much stock in training, manuals or tools...

Inexcusable....

Nubbs · 08-22-2006, 01:37 AM

I had the gaskets installed on my pickup under warranty. I still can't understand why they don't come with gaskets.

dvtech · 08-22-2006, 07:28 AM

[img]/ubbthreads/images/graemlins/smokin.gif[/img]you did'nt see that problem much on the 7.3L's. just bolts breaking off at times. egr system & excessive backpressure is the main culprit for this. don't you agree Grampy_jim & Ford Doctor? ford told me to just replace the manifold & bolts. [img]/ubbthreads/images/graemlins/wink.gif[/img]

red03f250 · 08-22-2006, 02:24 PM

Does anyone know how much to torque the exhaust manifold bolts and in what order? Want to drill and tap manifold for an EGT probe and don't want to take a chance of metal chips getting to the turbo. Thanks in advance.

rcchallenger · 08-22-2006, 05:30 PM

I also had the gaskets added under the warranty. It seems to have solved my exhaust in the cab problem.

MarkOomkes · 08-23-2006, 08:39 AM

[ QUOTE ]
Utterly amazing that some techs wont use the resources offered to them... I am led to believe that many dealers don't put much stock in training, manuals or tools...

Inexcusable....

[/ QUOTE ]

Still wondering what the chances are of getting one of you informed techs to move to my neighborhood. [img]/ubbthreads/images/graemlins/biggrin.gif[/img] I'd love to have you or Ford doctor around me instead of when I tell the service department my intercooler tube blew off and he says "It's a diesel, right?" I almost hung up right then and there but I'm in a bind and need that truck fixed ASAP and hope and pray they can do the job. [img]/ubbthreads/images/graemlins/shrug.gif[/img]

I've already given up on warranty repair of tranny's, but the engine repairs can be quite a bit more expensive.