TD5 Exhaust manifold failure

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Originally Posted by Tombie2

Guys...

Take a little look-see here:

TD5 Manifold Fix

Hopefully this will help those in the future.

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Yep did that, here's hoping it will be all good:D

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Originally Posted by Slunnie

Hey thats cool. I'll have to do one of those with the full grind next time I warp a manifold. I'm not decided about slotted holes though. I'm not sure it's good to have the bolts that loose or to have the manifold sliding under tension like that, but getting the flex happen in the manifold! Yeah! Loved the stainless job, thats cool!

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I did this mod after reading Tombies thread on it, i'm getting the new head modded with the bigger studs and fit my modded manifold on as well.

The mechanic was very impressed with the job i did on the manifold when i handed it too him (amazing what you can do with a 4" angle grinder:D), he did the bigger studs for me as i don't have the tools to do it, he also said he would recommend this mod to those anyone that came in with broken studs.

Baz.

Mine's a '99 manual TD5 D2 which I bought with 90,000ks on it. Chipped it around 100K's and studs have just gone at 160k's.

Mine went while under warranty, can't remember the mileage. Now chipped and at 113,000 kms, no probs since.

Regards
Max P

Mine just went at 190,000km.

Almost reluctant to get it fixed as it had developed a lovely howl on hard acceleration. :cool:

Now my clutch master is on the way out. :mad:

I've recently noticed the whistling so I guess I'm up for the fix. Any idea how much I can expect to be hit for the repairs? i.e. hours, materials.

thanks

02 Td5 112,000 chipped at 75k moderate off road use no towing

My car has 40k on it and nothing so far (as expected) but I'm watching this thread with interest.

'Ol Betsy is currently sitting on 203,000km's (01 Defender-not extreme), exhaust mods only(straight through pipe, no EGR), and no probs so far..................:angel:

The manifold on my Isuzu has smaller centre port bolt holes for location and larger end port holes so it can slide a little.

I heard a story of a cummins owner who overtorqued the manifold bolts and cracked the head as a result. That's an expensive lesson.

interestingly you don't have this happen on 300Tdi's as the manifold is a three piece casting and so allows for expansion. The centre two ports (and turbine housing) are a separate piece to No's 1 & 4 cylinders, and the two end manifolds are closely machined to slip inside the centre section.

Yep

2000 TD5 Defender chipped at about 90k. First manifold went at about 145k and she's gone again at about 160k.

Still hunting for someone on the Gold Coast to do the repair.

Brett