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AuthorTopic: D2 TD5 exhaust manifold studs sheared!  (Read 4180 times)

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Offline beast5680

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D2 TD5 exhaust manifold studs sheared!
« on: September 10, 2005, 21:03:35 »
i seem to remember somebody mentioning about exhaust manifold problems on TD5,s when they have been chipped, mainly about the manifolds warping and shearing studs, can anyone shed any light?
I have a friend who had his chipped about 3 months ago and called me round to check out a funny noise his had developed and i found the front 2 studs on the manifold have sheared causing an exhaust blow by on #1 exhaust port and wondered if this had been caused by the chipping and extra power it now has

suggestions to possible solutions most welcome
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Neal

let him that hath understanding reckon the number of the beast

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Offline thermidorthelobster

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D2 TD5 exhaust manifold studs sheared!
« Reply #1 on: September 10, 2005, 21:29:05 »
Quite possibly.  The Jeremy J Fearn upgrade seems to be the worst one for this, from what I've heard colloquially.  What upgrade is it?
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David French
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Offline beast5680

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D2 TD5 exhaust manifold studs sheared!
« Reply #2 on: September 10, 2005, 21:31:33 »
it is the jeremy fearn upgrade, what i,m after is whether the manifold had to be replaced on any that warped or whether you can get away with fitting new studs and retightening
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Neal

let him that hath understanding reckon the number of the beast

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Offline thermidorthelobster

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D2 TD5 exhaust manifold studs sheared!
« Reply #3 on: September 10, 2005, 21:52:48 »
The ones I've heard of have needed replacing, but I don't know whether that's always the case.  Interesting, thinking about this I've only ever heard of this happening with the JJF upgrade.  The performance seems to come at a price.
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David French
Tree-hugging communist
1999 Discovery II TD5 Manual
Patriot roof rack, QT Services diff guards front & rear, DiscoParts steering guard[/url], Autologic ECU upgrade, 2" Old Man Emu lift, 235/85R16 BF Goodrich All Terrains, Safari snorkel, DiscoParts jackable sills, Warn Tabor 9000

Ex Disco 200TDI, P38a 4.6HSE and 101FC 6x6 Camper.  Africa Trip Blog

Offline LOFTY

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D2 TD5 exhaust manifold studs sheared!
« Reply #4 on: September 11, 2005, 21:34:31 »
I posted about this, the existing manifold can be used after modding.
Use a die grinder to remove the thin webbing between the ports, this relieves a lot of the stress. Then get it machined flat, cost me £18.
Remove broken studs, fit new with locktight, use copper exhaust paste, very thin smear on both sides of new gasket, bolt into place, tighten studs with torque wrench, if possible.
Mine has been ok since.
 :)
The original posting has some photos of my manifold, it was about 3mm out of flat.
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Offline beast5680

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D2 TD5 exhaust manifold studs sheared!
« Reply #5 on: September 13, 2005, 17:43:09 »
cheers that will be the post i was thinking of then :D
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Neal

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Offline Wanderer

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D2 TD5 exhaust manifold studs sheared!
« Reply #6 on: September 13, 2005, 17:52:10 »
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Ed
1993 200tdi Snorkly

Offline beast5680

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D2 TD5 exhaust manifold studs sheared!
« Reply #7 on: September 13, 2005, 18:15:48 »
cheers ed
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Neal

let him that hath understanding reckon the number of the beast

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Offline Sharpshooter

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D2 TD5 exhaust manifold studs sheared!
« Reply #8 on: September 13, 2005, 20:59:00 »
I can machine it for you if that helps. Im near Ashford. :D
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