I have a totally stock 2002 7.3, and my question is for opinions on aftermarket exhaust manifolds and possibly new turbo. Both are working fine right now, but I do have a slight leak in one of my exhaust manifolds and they are both heavily corroded. My goal is to find replacements that maintain reliability and maybe a performance upgrade. Thank you for your opinions
Replacing the exhaust manifolds is a scary job. Every thing rusted like you say will probably mean broken manifold bolts, you should pull the engine for a job like that.
Depending on where the leak is, most likely the down pipe at the turbo, it's a slip fit. Black soot will be at the leak.
If you really want to fix the manifolds, just pull them and put in felpro gasket and new bolts. All can be done in a day easily. Just take a sawzall and cut the bolts in the opening between the manifold and head if you cannot get them out. I usually only need to cut a couple but on one truck had to cut all but 2 of them. Cut the bolt next to the manifold so you have a stud left to grip with a small pip wrench and they will come out. Always best to soak with PB Blaster for a few days before starting.
I have done on 5 trucks and not had any issue but the locator hole is smaller and rusted so the bolt will not come out of the hole but drill it out or heat will help.
I usually only do them when the back stud breaks on the manifold and causes a big leak.
My 96 pushes 36+ lbs boost with stock manifolds no problem, I would save your money on aftermarket ones and buy gauges, Chip, etc.
Thanks, for the info, I actually already have the gauges, and boost is working well as of now. Opinions are welcome so that I can research my options before actual failure. I have also seen a Youtube video where the bolts were cut like you suggested, and then a nut was welded on after removing the head which made it possible to remove the bolts.
I prefer keeping my setup close to stock because of the reliabilty issue, my truck is a daily driver and not a toy. I do have a Hyper-tech which allows changes electronically, and 4 inch stainless pipe from turbo back, but other than that, totally stock
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