Exhaust Manifold Leak

[66Sprinter]

Hey,

On my normal...stock engine...I was running hard today for about 1hr...(85mph) and then i noticed a ticking noise. Pulled over and checked it out..I have an exhaust leak at the twins exhaust port. Probably the gasket..but nonetheless...a noise that I dont like.

For fixes..I could (1) replace gasket or (2) add headers...so no problem there but money.....but I also have to prep the surface no matter what!

A few year ago..(mmm about 35!!!), I do remember installing a set of headers and the guy in my shop class had a long smooth file thingy..(cant remember the name) and he used it to buff the ports prior to installing gaskets. Good tool cause it buffed all the ports equal. It was long enough to cover all ports and not too wide. Does anyone remember or know of such a tool?

 

[mysavioreigns]

Sorry don't remember the tools name, but I've seen it before.

If you do take it off, get a port divder for those 2. I am pretty sure classic inlines has them.

 

[fordconvert]

The middle seems to be the most common place for them to crack. If you are going to keep driving it I would recomend disconnecting the choke heater tube and maybe going to an electric or manual choke. The intake for the choke is in the center of the manifold at the bottom most likely near the crack so it will suck up carbon and all sorts of other corrosive stuff and eventually ruin the choke housing and stat and plug up all sorts of passages in the carb... ask me how I know this.

Good Luck, hope you get all the bolts/studs out without breaking anything.

 

[66Sprinter]

TJ ...uh..how did you know!~

I got the manifold off....with a wrench, grinder, cutoff wheel, nut splitter and a few dozen choice "cuss" words. Spent more in gas than the gasket.

There was black carbon above and below the twins. Looks like a gasket blowout below and a crack in the exhaust header at the choke fitting. I did not save the gasket ...it came off in little tiny pieces..

Of course my wife is saying.."Do you know what your are doing?" and "Maybe you should just let a mechanic fix it!" ...when then sent me into a few more dozen cuss words...finally at 10pm...I am done. Standing there she asks "Are all those little box pieces..a gasket?"

I have three bolts still in....Any suggestions on getting them out with out major teardown or damage. Also..is is OK to use anti-seize on the new ones going back in?

Anyone have a spare header to sell?