Exhaust Manifolds | Warped

[ccsrt8]

I was at the dealership recently picking up a couple of parts and decided to ask the parts guy about how they address the manifold issue at a dealership. He said it is such a frequent problem that Mopar makes a full kit for each side, including a new manifold, gasket, heat shield and bolts. If ordered from an online dealer, the whole package comes out $200 - $300 cheaper than BD Diesel's kit (at least in Canada), approx $450 CAD. I asked the parts guy about why this would be a good option if they're still having problems with "near new" trucks. He said these had been revised and improved over the years. Obviously, I'm skeptical...

I'm curious if anyone's tried these out?

Passenger side part # 68591585AA

Driver's side part # 68591586AA

Some websites show them as a whole kit and others as just the manifold itself. But if it does come with everything, it may not be a bad deal, if they actually last long-term.

I tried asking the parts guy and also two other independent mechanic shops and none of them have tried the belt sander idea and since we don't have a machine shop within a 1 hour drive, none of the shops would want their hoist occupied for a few days waiting to get the originals machined. So all three said the factory replacement kits were their go-to for this repair. None have heard of or tried the BD diesel manifolds.

 

[danielmid]

New factory manifolds will eventually warp again, then you're back in the same boat. That's why the machining or belt sander method is recommended for the stock manifolds since they've already warped and won't warp again.

I haven't heard of anyone having the BD manifolds warp.

 

[ccsrt8]

Actually, I mis-spoke about one thing, one of the independent mechanics said they prefer to use the Dorman manifold kits, and they come with all hardware as well. Regardless, I'm suspicious of either kit, given reports on this site about guys having to re-do their repaired manifold a few years after the first fix. Unfortunately, I don't know anyone locally with a belt sander that I could make use of, so I'm stuck trying to figure out the best route for a permanent fix.

 

[danielmid]

Actually, I mis-spoke about one thing, one of the independent mechanics said they prefer to use the Dorman manifold kits, and they come with all hardware as well. Regardless, I'm suspicious of either kit, given reports on this site about guys having to re-do their repaired manifold a few years after the first fix. Unfortunately, I don't know anyone locally with a belt sander that I could make use of, so I'm stuck trying to figure out the best route for a permanent fix.

@Wild one know any machine shops in Vancouver?

 

[Wild one]

@Wild one know any machine shops in Vancouver?

Can't say as i do,i'm north of Calgary,so the lower mainland is a bit out of my stomping grounds,lol. Check your local Market Place or Ebay,you might find a big used belt sander for sale.I'm not even sure what you guys have for used tool outlets,but they're also a good place to hunt up used tools

 

[ccsrt8]

I'm on Vancouver Island now, so alot less resources than the Vancouver area, unfortunately, which includes Marketplace options.

I used to live only 15 minutes from the US border so I used to ship parts to my USA depot and go pick them up. But that's not an option for me any longer.

There are machine shops 45-60 min away but the local mechanics don't want their hoist with an immobile truck sitting on it for a few days while the manifolds get machined. Their feeling is that after you pay for freight & machining, you'll be into it for the same as the factory replacements. I'm not sure I agree, but it is what it is.

 

[TomT]

I know little about Canadian geography, but BD Diesel is in British Colombia.

BD Diesel Canada - Diesel Performance Parts & Products

At BD Diesel we design, create, manufacture & distribute diesel performance parts & products including turbos, intercoolers, exhaust manifolds, transmissions, torque converters, injectors, injection pumps, suspension, engine shut down controls, throttle controls, exhaust brakes & more.

ca.bddiesel.com

 

[ccsrt8]

Thanks for pointing that out. I kinda thought there was a location in BC, but it slipped my mind. It's probably the smartest way to go to fix the issue at this point.

Although, just for the sake of knowledge, I'd still be interested to hear if anyone has used the factory replacements and/or the Dorman brand with any success. Just to know all of the possible options.

I know little about Canadian geography, but BD Diesel is in British Colombia.

BD Diesel Canada - Diesel Performance Parts & Products

At BD Diesel we design, create, manufacture & distribute diesel performance parts & products including turbos, intercoolers, exhaust manifolds, transmissions, torque converters, injectors, injection pumps, suspension, engine shut down controls, throttle controls, exhaust brakes & more.

ca.bddiesel.com

 

[Gero]

What i did was i explained to the shop my issue and my plan, which is:
1. Have the shop remove both manifolds and call you
2. You pickup the manifolds and run home and belt sand them flat whilst the shop remove the broken bolts (I had 3)
3. Return to the shop with remflex gasket, dorman or oe hardware (also pickup the manifold to downpipe nuts too) and the sanded manifolds
4. They'll reinstall and call you when the truck is complete

The shop her in Ottawa was fantastic and they did a great job. Labour charge was also very reasonable too.

 

[Wild one]

I'm on Vancouver Island now, so alot less resources than the Vancouver area, unfortunately, which includes Marketplace options.

I used to live only 15 minutes from the US border so I used to ship parts to my USA depot and go pick them up. But that's not an option for me any longer.

There are machine shops 45-60 min away but the local mechanics don't want their hoist with an immobile truck sitting on it for a few days while the manifolds get machined. Their feeling is that after you pay for freight & machining, you'll be into it for the same as the factory replacements. I'm not sure I agree, but it is what it is.

It's usually pretty easy to find used stock manifolds,grab a set,and sand or machine them flat and take them with you if you're having a shop do the job,along with a set of Remflex 6022 gaskets.
Google auto wreckers in your area,as most will have a Ram being parted out

 

[ffeschjeff]

What i did was i explained to the shop my issue and my plan, which is:
1. Have the shop remove both manifolds and call you
2. You pickup the manifolds and run home and belt sand them flat whilst the shop remove the broken bolts (I had 3)
3. Return to the shop with remflex gasket, dorman or oe hardware (also pickup the manifold to downpipe nuts too) and the sanded manifolds
4. They'll reinstall and call you when the truck is complete

The shop her in Ottawa was fantastic and they did a great job. Labour charge was also very reasonable too.

I cant find a shop around me in Tulsa, OK that will even think about tackling the job...I did the passenger side myself with the sand it flat method but need to do driver side and would rather pay someone else to do it haha.

 

[ccsrt8]

Thanks for the good advice fellas. Gives me some things to think about. BD Diesel shows that they are out of stock currently, expecting to be available at the end of Sept, which would be fine since I'm not in any rush. But not sure that's the route I'm going yet.

I'm also looking into a local "mobile" mechanic that might be able to do the re & re at my place and then I could take my manifolds to a machine shop and have them trued up.

I've checked with a few neighbourhood car guys and unfortunately none of them have a belt sander, so I don't think that'll be a viable option for me.

I've seen mention of the Remflex 6022 gaskets several times. What's the advantage vs the factory or Felpro gaskets? Any concern about not having the heat shields if using the Remflex gaskets?

 

[Gero]

I picked up a belt sander at princessauto for $47 on clearance which was fantastic. I put the manifold on a vice and it took about 5 or 10min to get it pretty flat. It doesnt have to be perfect especially if youre using the remflex gasket.

 

[Hagar1]

Honestly man, i have never seen or heard of a warped exhaust manifold. I have repaired broken manifold bolts a lot of times and never had that issue of warpage. Thats new to me. Usually after removing the manifold and extracting the broken studs, the manifold mounting surfaces gets cleaned and a new gasket with hardware gets installed. Also, a heads up, sometimes the studs will not extract in the vehicle so the head will have to be removed. Then if studs wont come out after trying to extract them in bench, the head will need to be replaced. I have heard from techs at other dealers that they send them to a machine shop to get extracted and repaired. But in the dealers i have worked at, they never recommended doing that. Not sure how well that would work. Hope any of that helps.

I had a set of manifolds that were warped almost an eighth of an Inc when checked with a straight edge. It is indeed common for 5hem to warp and the long term fix is to get the old manifolds machined because a new set will warp and break some bolts ..... it is only a matter of time.
I had some broken bolts and got my manifolds machined. That was several years ago now and still no problem.

 

[PA Ram]

I installed BD Diesel manifolds almost 2 years ago due to broken bolts and warped manifolds. No issues, knock wood!

 

[Wild one]

Thanks for the good advice fellas. Gives me some things to think about. BD Diesel shows that they are out of stock currently, expecting to be available at the end of Sept, which would be fine since I'm not in any rush. But not sure that's the route I'm going yet.

I'm also looking into a local "mobile" mechanic that might be able to do the re & re at my place and then I could take my manifolds to a machine shop and have them trued up.

I've checked with a few neighbourhood car guys and unfortunately none of them have a belt sander, so I don't think that'll be a viable option for me.

I've seen mention of the Remflex 6022 gaskets several times. What's the advantage vs the factory or Felpro gaskets? Any concern about not having the heat shields if using the Remflex gaskets?

The Remflex 6022's are a thick graphite gasket that will absorb expansion and contraction with out breaking bolts,better then a multilayer steel gasket will. Just don't bend/flex them,as they don't take kindly to being bent.
As stated check out Princess Auto or your local hardware stores for a belt sander,then aren't hard to find,Canadian Tire has a bunch of them, Amazon probably has a bunch of them to.

general-plp-template

www.canadiantire.ca

 

[ccsrt8]

Damn, those Remflex's are expensive! My first car cost less...and I'm not actually kidding!

 

[Wild one]

Damn, those Remflex's are expensive! My first car cost less...and I'm not actually kidding!

JB's in Edmonton will ship them.

Remflex 6022 Exhaust Gasket-MOPAR V8, Hemi, 370/6.1L

V8 - Hemi 370/6.1L ('05-'10), D-Shaped Port 1-15/16" x 1-3/8", 2/Set

jbspowercentre.com

 

[ccsrt8]

Thanks, I'll have to start assembling the parts for the project. Dorman fasteners, or stick to OEM? And is there a kit from OEM or do they only sell them one at a time?

 

[ccsrt8]

JB's in Edmonton will ship them.

Remflex 6022 Exhaust Gasket-MOPAR V8, Hemi, 370/6.1L

V8 - Hemi 370/6.1L ('05-'10), D-Shaped Port 1-15/16" x 1-3/8", 2/Set

jbspowercentre.com

Doesn't look like they'll ship to BC, but I found that Lordco has them listed at nearly the same price point. But thank you for the suggestion.

I've found a local neighbour with a lift and a mig welder, so I might be able to tackle the re & re with his help.

Now I'm looking locally for a machine shop that might be able to mill the manifolds flat.

Then I can start assembling the parts I need to get the process started. Any thoughts on best options for the fasteners?