Repair Exhaust Manifold - Defender Source
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  #1  
Old December 12th, 2010, 10:07 PM
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David Short
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Repair Exhaust Manifold

Can you repair an exhaust manifold? How?
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  #2  
Old December 12th, 2010, 11:20 PM
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I'm guessing a machine shop or anyone familiar with dealing with cast iron can weld it. I took a welding course at NOVA in manassas, and although the instructor I had died, I think they might continue his policy of helping people with projects as they can demo the technique to students. Might be worth looking into if a machine shops quotes you a high price.
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  #3  
Old December 13th, 2010, 08:20 AM
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Just thru bolt it.
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  #4  
Old December 13th, 2010, 09:57 AM
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A good welding shop can do that easily.
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  #5  
Old December 13th, 2010, 04:39 PM
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Just cut it flush and drill it out. I do it in the vehicles all the time.. You may be able to drill and retap it if you take your time with it.

The through bolt is a good way if you get your hole to big or off center.

Ship it to me if you need help. Really just a few minutes to sort.
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Old December 13th, 2010, 04:47 PM
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I got the impression the crack in the flange was the issue, not the stud (which admittedly looks rough and should be replaced).
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  #7  
Old December 13th, 2010, 07:42 PM
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i would say get a new one if it isn't terribly dear.
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  #8  
Old December 13th, 2010, 11:35 PM
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Post a picture of the manifold complete then. I may have some old grey market pieces that would match it I could let go of cheap. Did not see the crack. Through bolt or scrap it. May be best to scrap it.
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  #9  
Old December 14th, 2010, 02:57 AM
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Just get another v8 manifold
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  #10  
Old December 14th, 2010, 08:45 AM
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If you want to try to reuse the manifold, do like Pendy said and cut off the stud. Grind out the crack until you have a narrow v notch. Use nickel rods for cast iron to weld up the notch. Heat the manifold in an oven as hot as you can get it before you weld it to prevent further cracks. After the repair, dress up the weld with a grinder and drill and tap. An alternative to the welding is to braze it. I've done many a series manifold with good success. Later V8 manifolds will allow better performance but you will need to rework your exhaust downpipe.
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  #11  
Old December 14th, 2010, 09:45 AM
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Photos of complete manifold

Here is the complete manifold. The PARTS BOOK says it is part # ERC 3482 and that is what the number on the side of the manifold appears to be, as well.

If anyone has this laying around.... love to entertain some negotiations.

If there are no easy replacement parts.. I will put this to the side for a few more days / weeks until I get the rest of the engine comepletely sealed up. I do not want to start any grinding or welding dirt in the garage until the engine is safely sealed. (I have it wrapped in plastic between work nights at the moment but am still worried about dirt and dust.)

If I re-use this part then I will definately look into stud replacement.
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  #12  
Old December 14th, 2010, 10:46 AM
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Are the center dump mani's all that important? Will the rear dump ones work? You can fix it with epoxy if you really love those things.
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  #13  
Old December 14th, 2010, 11:21 AM
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doubt this will help, but....

----------------------
From: "d.h.lowe" <dhlowe@idirect.com>

Date: Wed, 20 May 1998 12:04:20 -0400
Subject: Re: Stage One V8 Exhaust Manifold

Have to disagree. I have just been through my microfiche and find the
following..............Vehicles built to ECE 15.03 standard....Left hand drive
ONLY. use part no.7176 for the right hand manifold and 7174 for the left hand
manifold.
Detoxed engines up to engine no. 11G00855 use part no.ERC4720 for the right hand
manifold and ERC3101 for the non detoxed right hand manifold. The left hand
manifold is ERC3482 These are all 109 V8 numbers. The Range Rover
manifolds
up to Oct 1985 are ERC5925 right hand and ERC5069 left hand for engines 11D.
15D. 16D. 17D. 19D. 20D. 21D.................Detoxed engines 355,359 suffix A,B
use 611520 r.h. and also ERC3101 r.h the left hand is ERC5069
.........Australia
vehicles ,engines 398 suffix F. use ERC2994 r.h. and ERC2992 l.h. .........I
have
been through later R.R, 110, and 90 ( which have another large list of
manifolds)
and cannot find a 2995 If your manifold is the plain rounded type with a centre
outlet pointing straight down and no heater box you might try a SDI car
manifold.

> << 'm in need of a new (Right Hand) Exhaust manifold for my Stage One V8 109.
> Mine's cracked and the Rover# is ERC2995. The problem is that nobody has any
> record of that number existing. >>
> Ted,
> I've got part no ERC 7174 for left hand drive (ERC 7176 right hand drive) in
> my parts book. Try your dealer on that.
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  #14  
Old December 14th, 2010, 04:28 PM
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Quote:
Originally Posted by LRover View Post
If you want to try to reuse the manifold, do like Pendy said and cut off the stud. Grind out the crack until you have a narrow v notch. Use nickel rods for cast iron to weld up the notch. Heat the manifold in an oven as hot as you can get it before you weld it to prevent further cracks. After the repair, dress up the weld with a grinder and drill and tap. An alternative to the welding is to braze it. I've done many a series manifold with good success. Later V8 manifolds will allow better performance but you will need to rework your exhaust downpipe.
If you do this make sure you specify machinable nickel rod or you will never be able to drill/tap it.
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  #15  
Old December 18th, 2010, 02:40 PM
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David, for those projects I higly reccomend jensen manufacturing and machine services in lorton off telegraph rd.
about 1/4 before rt 1 if traveling west on telegraph on the right same building as C and C alternator.
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