DIY: Removing Bed and QuadCab to replace Exhaust Manifold Gasket

AlohaRam · Jan 2, 2013

I recently purchased a 2002 QuadCab with the 4.7L V8... The seller thought it needed new Exhaust Manifolds. Turns out that the 2 rear exhaust studs on each exhaust manifold broke, causing the gaskets to blow out.

I don't know much history on this truck, but apparently it was driven thru salt-water.

Prior to this journey into replacing the exhaust gaskets, the engine and transmission oil pans began to leak. They were rusted so badly, I was able to poke a hole in each with a screwdriver. So I replaced both pans with new.

My Exhaust Manifold Journey >>>

The source of exhaust leak...

What I started with...

Accessing the rusted Manifold Bolts...

At last, the 34" clearance needed to roll out the chassis...

Full Access...

Attacking the rusted fasteners...

All 16 bolts out! ...

To be continued...

emjohn4 · Jan 2, 2013

Holy chit! Thanks for the pics!

Great job! Any other plans while you've got it apart?

Casper · Jan 2, 2013

Nice thread: Unfortunately it looks like you've got a lot more preservation to do while you have the access.

An Island car/truck is bad enough, but that's some serious neglect. :banghead:

TexasRammer · Jan 2, 2013

Damn nice job, youre putting some serious work into that

smiley · Jan 2, 2013

Chewy · Jan 2, 2013

Well played!

AlohaRam · Jan 2, 2013

Thanks!...

I've been working on vehicles in Hawaii for 35 years, and never seen salt damage this severe. Some idiot got this Ram deep enough where the fan splashed salt water everywhere, and it was never rinsed with fresh water.

Aside from rusted bolt heads, fortunately the engine has no real damage. I peeked under the intake manifold, and it looks like the engine block is shedding its skin there too... so I'll be pulling off the intake next.

Actually, I've been a Chevy/GMC fan all my life... never had a liking for Dodge. However, although this is a "bulky" job, it has to be the easiest thing I've taken apart in a loooong time.

These are the only tools I needed to disconnect the cab from the chassis:

It took me 2 hours to disconnect/lift bed and 4 hours to disconnect/lift cab...

So yah, I am now a Ram fan! :rockit:

I got half the frame painted on NewYear's eve, but it rained all day yesterday... I'll post more pics later.

AlohaRam · Jan 2, 2013

emjohn4 said:
Holy chit! Thanks for the pics!

Great job! Any other plans while you've got it apart?

I'd like to do some performance upgrades while I have it apart, but this is a "flipper" for me, so I am trying to keep it low-budget.

However, If I can find another QuadCab cheap enough ( with a bad engine or trans ) , I'll swap Chevy Power into it...

TexasRammer · Jan 2, 2013

dang thats pretty impressive! and welcome to the site!

WhiteExpress · Jan 2, 2013

Wow! That thing looks terrible! I'd hate to see the alternator & starter.
Not to mention the billion other electrical connections.

AlohaRam · Jan 2, 2013

TexasRammer said:
dang thats pretty impressive! and welcome to the site!

thanks, and thanks!

AlohaRam · Jan 2, 2013

WhiteExpress said:
Wow! That thing looks terrible! I'd hate to see the alternator & starter.
Not to mention the billion other electrical connections.

It actually looks worse than it is.

The Alternator & Starter work fine... for now.

All of the electrical connections are fine...
and aside from the redundant safety locks Dodge uses on the connectors,
they were all easy to remove.

The salt corrosion mostly affected "bare" metal components,
including the "steel":

fuel rail...

atf cooler lines...

p/s lines...

and brake fluid lines...

Both brake fluid lines broke apart with very little force.

AlohaRam · Jan 2, 2013

watching a non-stop drizzle wash away my hopes of having this job done by tomorrow...

AlohaRam · Jan 2, 2013

Under the intake manifold....

First Aww-**** moment of the job,,, broken dip-stick tube...

Chewy · Jan 2, 2013

Oh wow!!! That thing's pretty bad!

Sent from my iDevice using data nodes and algorithms.

AlohaRam · Jan 3, 2013

.
Engine & Trans Harness...

Got the loose rust cleaned up,,, which would you choose to treat the bare iron block to prevent further corrosion?

Chewy · Jan 3, 2013

Is the blaster rated for heat? The paint IMO would be a waste... It needs clean metal to stick to, and that's ANYTHING but clean IMO.

How about that stuff that turns rust into a black hard coat? You can get it at local auto parts stores usually. I wonder if it'd work with heat.

emjohn4 · Jan 3, 2013

AlohaRam said:
.
Engine & Trans Harness...

Got the loose rust cleaned up,,, which would you choose to treat the bare iron block to prevent further corrosion?

Look at POR-15 line of rust preventing paints - might be your best bet.

Casper · Jan 3, 2013

Not sure why the love for gub'mnt motors power. Seen a lotta of failure down that road.
Of course it is your money.... :crazy:

AlohaRam · Jan 3, 2013

Casper said:
Not sure why the love for gub'mnt motors power. Seen a lotta of failure down that road.
Of course it is your money....

Bwahaha... like your sig...

Simply brand loyalty... :boti:

Although I wouldn't dump a Cummins for any GM Power.

DIY: Removing Bed and QuadCab to replace Exhaust Manifold Gasket

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