Thread: Technical help - Exhaust Gasket Manifold - Td5 - please help!

OK No 1, welcome to the joys of LR spannering! ; No 2, mistake was not replacing all the studs with new, even with new original size 1s; No 3, In my experience You can fluke reusing a crushable tin exhaust gasket providing it was torqued evenly and not started. Check its surface when you take it off and if there is not any evidence of damage,ie the surfaces are not flat and even, kinking etc, you can probably use it. The reason being for no damage is the fact the gas pressure is higher having to flow past the turbo vanes. If in doubt bin it, no sense in all that work to be undone by a few dollars of tin!
Cheers Scott

if youve snapped one of the M8 studs, leave the manifold in place, get the busted stud out and replace it with another one. you will need to be very very precise and you want a left hand drill to start the drilling with...

if you have to remove the manifold do not reuse the gasket.

did you slot, moon, cut or remove the casting webs while the manifold was off?

if you didnt, let this be the point where you have the awakening that the landrover gods have smiled at you and given you a warning and a second chance to do it right the first time...

Good responses, thank you.

I did not cut the webbing but I do as I do have the right tool for the job.

Yes I certainly should have changed all the studs in hindsight

I will try the tap, centre drill and left hand drill out in situ, first.

If this doesn't work and assuming the gasket cannot be reused, does anyone know where I can get one at short notice in Brisbane? I live Northside and am now limited to bicycle or public transport.

Admittedly I did decide to go for it, slightly underestimating the complexities of the job.

I'd suggest that you replace all the studs with M10's and also ensure that there is cllearance around each stud when refitti g the manifold. This may require either drilling or filing the manifold holes so that it slips over the new studs easily.
Torque it up nice and evenly with a new gasket and you won't have to revisit it again.

Thanks for all your advice.

Problem solved for now..

Didn't have/couldn't get another gasket and couldn't get a left hand drill bit. So to get me going again I drilled out the broken m8 with the manifold in situ with the drill bit for the m10 bolt hole. Cut a new thread, then drilled out a m10 sized hole in the manifold whilst in situ so that I get the new m10 stud through. Popped the new flange nut on and bobs your uncle.

Not perfect as I would like to have replaced all studs with m10 as suggested but deemed it too stressful to do the remaining 8 with the manifold on and couldn't take it off due to gasket already crushed etc.

Next time the manifold is off will replace all with m10s.

Consider me in the aulro fold now. You guys are really helpful thanks.

James

for later reference, for NIRTS parts you need MR automotive on 0732846688. to brisbane its almost always next day delivery sometimes same day.

if you're after routine parts you need roverlord.

G'day Guys

I have to remove my exhaust manifold and replace the gasket.
I see a lot of talk around replacing the stud bolt with M10. Firstly what length do I need.
Also going up to M10 will that cause any head issues later.
And what is the best way to go about the manifold removal etc.

Rocky.

Hi all, seeing as this is up and about.
My first TD5 had M10 studs for the first and last ports but I had hells own job of getting the gasket stud holes drilled out to suit, how do you do it?

Cheers

Mike