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Speaking of Cummins Diesels......

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robertmn

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Hello to all; We have a 300hp,24 valve engine in our 2001 Discovery pusher. Today, I was ck'ing things over, for our Ca. trip. I found the exhast manifold is broke in half! It's broke 3/3, all the way around. 29K miles. I know Cummins has problems with these. Has any one changed one....Should a person go aftermarket 3p.? Or stock? Thanks Bobmn
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Hello RobertMn,
Cummins manifolds were usually a 3 pice design in the class 8 trucks. That crack you have is the reason for that setup.
I would definately go with the 3 piece unit.
Guido.
 
Why can't you weld that? Put a couple tacks while it is still on the engine. Carefully remove it, and braze it. I feel that the higher temperature of brazing will have more of a stress-relieving action than the localized heat of arc welding, which, if it warps the casting somehow, will become stressed as it is tightened against the head.
 
just replace the manifold with oem one or an ats manifols . you might have to go with a cummins manifold. Because of the placement of the tubro.Its proubly a low mount rear out. I would check the carge air cooler most of the time you get a cracked manifold .Is because of a low boost condition and your egt's are to high. and the excessive manifold temp. will crack the manifold after a period of time. Your engie is around 300hp. john
 
get out the {RED GREEN SPECIAL REPAIR TOOL], DUCK TAPE to repair it...lol... i would check with dealer/cummins to see if recall or warranty, with low miles,,worth a try.. they might tell you which manifold to get/use...
 
The truck engines have a 3pc manifold because they have 3 heads. That looks like a b engine which has a single head. the turbo hangs directly below that crack and it looks like the cold side tube contacted the exh manifold. you might need what they call a kick stand on the turbo to keep it from twisting and touching the exh manifold.
 
my dad's pusher motorhome did the same thing, he replaced it by himself, take the bed out to allow better access to the engine. as far as i know he had no problems with removing it ,
 
After you replace it. be sure and blow out your charge air cooler and water radiator. I would say you are full of bugs and bee's wings (comes from corn). Vic
 
I'd try a Cummins DISTRIBUTOR rather than a dealer. Nothing wrong with dealers but distributors have a direct link to the factory and Cummins now own 49% of their distriburor network. The only exception is if you have a well connected dealer that is willing to go to bat for you.
Your failure is a known problem, there are aftermarket manifolds to correct it. Cummins may now have a three piece manifold. I worked there on the original design team of the B series engine but left to join another company 15 years ago.
If you strike out with Cummins dealers and their distributor network you can call 1-800-DIESELS and complain, it rings at their headquarters in Columbus, IN. Next step is to Google Cummins B series manifold. Be careful, there are several different turbo locations, you want a manifold that bolts right in place. Be sure to have your engine serial number when contacting a Cummins dealer or distributor. It was located on the front (timing) cover when I was there, not sure if it still is.
 
There is another problem somewhere.At 29k miles there is no reason bolt heads should be cooroded as photo shows.Also photo shows that part of manifold has been very overheated by color shown.I have a 2007 with 39k on an there is no part of manifold or bolt mountings showing coroded bolts or color as yours does. before You need to check engine an find problem before running with new manifold.
 
An exhaust manifold gets too hot for brazing. A block could be brazed but not the exhaust manifold. At night the manifold will glow because it's so hot.
 
I just replaced mine on my 24 V Dodge 3500 I went with the three piece. It was a much heavier unit with larger runners and a lot thicker casting. Mine cracked at 38,000 Miles.
 
Hello to all!! Thanks to all!! First of all, to clear up a couple of things....the " hot spot" on the maniflod is my bright flashlite, so it would show up the pic. Also the rusty bolts and stuff...we live on a gravel road up in northern Mn. Humid and high water table is tough on everything!! WJD...thank you for the #'s. I did get the motorhome in the shop, and got the rear half of the manifold off. I had to make brackets to hold the bed up at a higher angle. I think making room in the shop was harder!! (just kidding) Still have the tubo, and stuff to remove. Thanks again...BobMn
 
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