Fix It

Replacing the exhaust manifolds on your Ford F-150 truck is a complicated process that varies greatly depending not only on the year of the truck but also the type of engine. The manifolds are connected to the cylinder heads and the catalytic converters. You should talk with your mechanic before attempting this type of repair.

Instructions

V6 Engines

1

Disconnect the trucks negative battery cable, then raise the truck and securely support it on jack stands.

2

Disconnect the electrical connectors to the oxygen sensor.

3

Remove the nuts connecting the exhaust Y-pipe to the manifolds. Apply penetrating oil to the nuts and studs, if necessary.

4

Remove the engine lifting bracket. For the drivers side manifold, remove the dipstick tube from the oil pan by removing its nut and pulling it out. For the passengers side manifold, disconnect the EGR pipe from the manifold.

5

Disconnect the six mounting nuts for the exhaust manifold. Separate the manifold from the cylinder head and remove the old gaskets.

6

Place the replacement exhaust manifold with new gaskets onto the cylinder head. Install the mounting nuts with a torque wrench, tightening the center nuts first, followed by the front pair and the rear pair.

7

Reconnect and install the other components in the reverse order of removal--this can include the engine lifting bracket, oil dipstick tube, EGR pipe and oxygen sensor electrical connector.

8

Lower the truck and reconnect the battery cable.

V8 Engines

9

Disconnect the negative battery cable, raise the truck and support it on jack stands. Remove the inner splash shield from the fender well.

10

Disconnect the EGR pipe at the EGR valve and exhaust manifold if you are removing the drivers side manifold on a 4.6 liter engine. On a 5.4 liter, remove the front and rear heated oxygen sensors and the exhaust support bracket.

11

Remove the starter if youre removing the passengers side manifold. Also remove the stabilizer bar on a 5.4 liter engine.

12

Disconnect the catalytic converter assemblies from the manifold on a 5.4 liter engine by removing their nuts, then move the assemblies to the rear of the truck.

13

Remove the mounting nuts from the exhaust manifold and remove it. Remove the studs from the cylinder heads and discard them and the nuts.

14

Clean the mating surface on the cylinder heads, using a gasket scraper to remove any carbon deposits. Install new studs into the cylinder heads.

15

Place the exhaust manifold over the studs with new gaskets. Install new mounting nuts, working from the rear to the front and alternating between the top and bottom rows.

16

Install the remaining components in the reverse order of removal and lower the truck. If you need to reconnect the EGR pipe, apply a small amount of anti-seize compound on the threads.

A free flow exhaust is a type of system installed in vehicles for increased power and a sporty look. They are designed to remove engine emissions more efficiently than standard exhaust systems.

Purpose

Free flow exhaust systems are designed for looks and increased efficiency and power in vehicles. They are typically made of 100 percent stainless steel, which offers a nice sporty look. They weigh less than standard exhaust systems, which helps account for increased fuel economy and improvement in acceleration.

Process

Exhaust systems are used for removing spent gas from a vehicles engine; theore exhaust systems play a role in engine tuning and performance. A free flow system allows the spent gas to exit the vehicle more efficiently by changing the pipes used in the system and installing an intercooler between the engine and the exhaust.

Benefits

With a free flow exhaust system, a smoother removal of spent gas is offered. Because of this, vehicle owners notice an improvement in the overall way their vehicle runs. These systems promote better gas mileage and increased acceleration as well.

The exhaust system of a car is designed to carry away the harmful and toxic gases produced by the engine. The quicker these gases can be channeled away from the engine, the better its performance. Even the smallest crack or hole in the exhaust can reduce the overall efficiency of the car. There are numerous ways to patch an exhaust; however, some are better than others.

Cut a Section Out

If there is only one small section of the exhaust pipe that is damaged, you can simply remove it. This is a simple procedure that can be done with basic tools. All that is needed is a pipe cutter, a welder and a good eye. The biggest problem with cutting away a section of the exhaust pipe is getting to it. Unless you have a sunken pit in the garage, some jacks may be necessary to raise the car. By cutting away the damaged section, and welding the remaining pipe back together, the exhaust will still be able to function. However, efficiency will be lost. Pieces of pipe can be purchased from garages that will join together and replace a damaged section of pipe. This can prevent the exhaust pipe from becoming too small.

Heat-Resistant Material

The problem with attempting to patch an exhaust without using proper equipment is that the exhaust heats up considerably. Most material applied to patch a hole in an exhaust will burn away after the car has driven a few miles. A creative solution is to use fire-retardant and heat-resistant clothing, available from work clothing outfitters. Basic heat-resistance gloves can withstand temperatures up to 1,500 degrees Fahrenheit. This is more than capable of coping with the 300 to 520 degrees Fahrenheit that is the average temperature of an exhaust. Using a glove or piece of material to stuff into a hole is only a temporary measure, however, as the material may become dislodged as the car travels.

Use a Bandage

Not the most creative solution, but one that works, is heatproof gum. A small crack or a hole can be quickly patched up by applying this versatile material, available from most garages and hardware suppliers. The heatproof gum can come as a paste, a gum or as an actual bandage that you can wrap around any damage on the exhaust. The material is treated to ensure it can withstand the temperatures of the exhaust, and some brands of heatproof gum are designed to act as a permanent solution rather than a temporary measure.

An exhaust is an important vehicle component that funnels and scrubs engine byproducts while reducing engine noise. Stainless steel is one of two basic types of exhaust materials. The other material is regular steel. Stainless steel exhausts are less likely to rust and can be visually more appealing.

More Durable

A stainless-steel exhaust is less prone to rust, according to the online automotive magazine Matey-Matey. The rust process is extremely slow, compared with regular steel that can rust within three years of use. Stainless steel exhausts vary by grade: The lower the grade; the better the exhaust. For example, 304 and 316 grade exhausts are superior to a 409-grade exhaust, which offers less resistance to corrosion, though still better than regular steel.

Visually Appealing

Stainless steel is more visually appealing, because its not likely to rust and discolor. In addition, these exhausts initially have a polished finish and brilliant shine. As long as you keep the exhaust system clean, the finish retains its original appearance and does not tarnish.

Emits Fumes Faster

According to Stainless Online, a stainless-exhaust kit manufacturer, stainless-steel exhausts are more efficient ventilation systems, which reduces heat buildup in the engine. This may justify their increased cost. Matey-Matey says several stainless steel exhausts come with a lifetime guarantee.

Life-Time Guarantee

If you have a motorcycle with a dented exhaust pipe, you can easily repair it yourself without spending a great deal of money. With just a few tools and some time, youre motorcycle exhaust will be fixed in no time. In most cases, you will be able to restore the exhaust shape by as much as 95 percent, which isnt perfect, but is quite an improvement.

Instructions

1

Run water through the entire exhaust system two or three times in order to ensure that its clear of fresh gas deposits (if the exhaust has excessive carbon deposits, remove all previous deposits before pressurization). Seal both ends of the exhaust and tighten the expansion block plugs (the expansion block plugs should be located far enough in to attach vice grips on each end of the exhaust). Attach the vice grips (one small one on each end).

2

Hook the exhaust pipe up to an air compressor before pressurizing the system. Pressurize the system (between 80 and 120 PSI). Heat each dented area with the map gas system to a red glow slowly (the dents may start to come out), keeping the heated area pointed away from you. Tap out the dents (moving in circles around dented area) with your hammer.

3

If the seams split due to excessive heat, use the welder to seam the splits back together. If you are not well-versed in the use of a welder, you may have to take the exhaust to someone who can do this portion for you. Turn on the drill with the wire wheel attachment. Apply the wheel with a great deal of pressure to any areas that are discolored until the discoloration is reduced or completely removed. Polish the exhaust using a clean towel to remove any final discoloration.

Exhaust problems are reasonably easy to pinpoint, but if not repaired, they can cause noise pollution or even pose a danger to the people in your car. Luckily, with the many good exhaust repair products on todays market, exhaust repairs are easily fixed.

Exhaust Repair Kits

A good exhaust repair kit should include steel plates, as well as steel seamless tubing fitted for a quick connection to the exhaust and the fittings. Some repair kits come with a high-temperature steel cold weld, resistant to corrosive exhaust heat and gases. An exhaust kit should also include a reinforced screen or bandage for extra support and easy to use and understand instructions.

Exhaust Bandages

An exhaust bandage fixes exhaust rips and tears and lasts for quite a while or even permanently. The smaller the leak or crack, the better a bandage fix will work. Exhaust bandages are made of epoxy-impregnated fiberglass or of ractory strips and are resistant to the high temperature and the corrosive fumes of the exhaust. An exhaust bandage is molded into the small holes or cracks of the exhaust. Then it chemically welds to the exhaust, muffler or tail pipe and your exhaust is repaired.

Exhaust System Sealers

An exhaust system sealer acts as a chemical weld or a ceramic seal and is meant for fixing small holes and cracks. It can be water-based and should be asbestos free. It sometimes contains fiberglass fibers to hold the sealer in place while it cures. Like any exhaust repair product, it should withstand high temperatures. Exhaust sealers should also be resistant to chemicals, solvents, aging and oxidizing.

Exhaust System Repair Tape

Exhaust system repair tape is made from aluminum and a high-temperature bonding agent. It stops the noise a damaged exhaust makes and will seal out dangerous fumes. It works well for smaller exhaust problems, but seldom is a permanent solution for larger holes or cracks.

Exhaust Repair Tools

For a do-it-yourself job, the car should be on wheel ramps or an axle stand. Eye protection is also needed since rust flakes or metal shavings can get into your eyes. Metal snips or cutters and muffler clamps are needed. If jubilee clips are used to clamp the new part onto the exhaust, a screwdriver to fit the clips is necessary. A pair of pliers to pry off the bad exhaust parts is also useful. A pipe expander or a crimper to fit the new part onto the exhaust is also needed.

The purpose of installing an exhaust system on your vehicle is to reduce the amount of toxic emissions from your engine and to help reduce the noise level generated by your engine. Having a good exhaust system can also increase your engines performance. This can increase horsepower and the gas mileage of your car or truck. This project if fairly easy and can be done at home in your drive or garage with a simple set of tools.

Instructions

1

Take a pad of steel wool and caully clean the mounting surface that attaches the exhaust system to the engine headers of the vehicle.

2

Put the exhaust gasket on the mounting surface of the header. Align the mounting holes of the exhaust system with the holes on the engine header. Insert the mounting bolts and use your hands to loosely tighten them in place.

3

Connect the exhaust system to your cars exhaust hangers. These hangers have a rubber loop at the bottom. Take the metal hook from the exhaust system and attach it to the loop.

4

Use a socket wrench to finish tightening the bolts that are connecting the exhaust system to the headers on the engine.

5

Remove the jack stands and use the jack to lower the car back down to the ground.

The exhaust manifold connects directly to an engines cylinder ports and routes chemical-laden exhaust gases out toward the tailpipe. The seal between exhaust manifold and cylinder ports must be airtight for safety and emission reasons. You may use sealant along with a gasket.

Function

The exhaust manifold plays an important role in engine performance and longevity. Combustion within the engine cylinders creates waste gases expelled through the exhaust system, which begins at the exhaust manifold. You must maintain an airtight seal between cylinder ports and manifold.

Applying Sealant

Every professionally installed exhaust manifold and cylinder head have a gasket compressed between them. Age and engine heat wear gaskets down, reducing the quality of seal between the two components. Though sealant adds seal protection, new gasket installation does not require it.

Safety

A leaking seal or cracked exhaust manifold allows harmful exhaust gases such as carbon monoxide into the vehicle cabin. Carbon monoxide impairs motor functions and in large doses can cause death.

Volkswagens replacement for the Beetle in the mid-1970s was the Rabbit, a compact hatchback sedan that sported a transverse-mounted water-cooled four-cylinder engine. The Rabbit nameplate was discontinued after 1984, but a small VW using the Golf nameplate continued on. The Golf name was changed back into the Rabbit in 2006. The 2007 Rabbit is similar to earlier Rabbit and Golf models. The exhaust system on the Rabbit routes harmful gases from the engine to the rear of the car. The first step in replacing a rusty or damaged exhaust system is to remove the existing one.

Instructions

1

Drive the car onto a set of automotive ramps and set the parking brake. Shut off the engine and allow it to cool. Chock the rear wheels to prevent unwanted movement.

2

Don a pair of safety goggles and a pair of heavy work gloves. Crawl under the vehicle and locate the exhaust pipe where it routes over the rear axle. Cut completely through the pipe in this area with a hack saw.

3

Locate the rubber isolators that the rear section of exhaust is hanging from. Lift up on the exhaust pipe to the rear of the saw cut and slide the rubber isolators from the hooked ends of the exhaust hangers. Remove the rear section from under the car.

4

Loosen the bolts on the exhaust pipe clamp on the center section of the exhaust pipe with a socket and ratchet wrench. Lift up slightly on the pipe, then slide the rubber isolators on this section of exhaust off of the hooked exhaust hangers. Remove the center section from under the vehicle.

5

Loosen and remove the retaining nuts on the extension pipe of the exhaust at the front of the vehicle at the exhaust manifold. Lower the extension pipe and remove it from the vehicle.

Though it may seem unneeded, a change of the exhaust system on your Honda can make a world of difference. Also, exhaust kits can be relatively cost-affective and easy to install. The process of replacing exhaust can be done without any specialized mechanical knowledge.

Instructions

1

Back the vehicle on to blocks, or use a jack to raise the rear end of the vehicle.

2

Use a standard flathead screwdriver to remove the hose clamp from the joint between the muffler and piping. Also, unscrew the mounting clamps that keep the muffler attached to the bottom of the vehicle. Pull the muffler off the piping and away from the vehicle.

3

Remove the hose clamp that attaches the piping to the exhaust port. Remove all of the mounting clamps that keep the piping attached to the vehicle. Remove the piping.

4

Replace the old piping with newly purchased piping. Make sure to place heat-treated silicon around any joints. Attach the hose clamp to the exhaust port joint, and replace all mounting clamps.

5

Replace the old muffler with a new one. Again, place heat-treated silicon around the joint. Attach the hose clamp to the joint between the muffler and the piping, and replace all mounting clamps.

A vehicle exhaust system carries toxic fumes generated by the engine away from the passenger compartment. When an exhaust system leaks, exhaust fumes can flood into the passenger compartment, along high levels of carbon monoxide. Carbon monoxide cause headaches and can even cause passengers in the vehicle to become unconscious and eventually die.

Instructions

1

Raise the vehicle with a floor jack positioned at a secure point recommended by the vehicle owners manual. Stabilize the vehicle by placing a jack stand under each side of the vehicle frame. Lower the floor jack.

2

Remove loose dirt and debris from the area around the exhaust hole with a clean rag.

3

Scuff the area around the hole with 600-grit sandpaper.

4

Spray engine degreaser on the area surrounding the hole. Allow the cleaner to sit on the exhaust for 10 to 15 minutes. Wipe the engine degreaser from the exhaust with a clean rag.

5

Wrap the exhaust pipe starting two inches to one side of the hole. Continue wrapping until you overlap and past the hole by two inches.

6

Cut the exhaust repair tape with a utility knife.

7

Run a plastic squeegee over the applied exhaust repair tape to remove air bubbles and secure the tape to the exhaust.

8

Raise the vehicle with the floor jack. Remove the floor jacks. Lower the floor jack.

When the exhaust manifold studs break on a Ford F150, the driver will notice a puttering sound on cold start-up because the backside of the exhaust manifold will vibrate, smacking into the engine head. Eventually the oxygen sensors can receive erroneous readings due to an increase in the oxygen passing over the sensor. This could possibly lead to engine performance problems from the change in fuel trim values. In extreme cases your check-engine light might pop on. With the use of pneumatic tools and a long afternoon you can take care of problem.

Instructions

Set Up

1




Determine which manifold is leaking by looking on the backside, closest to the passenger compartment, with a flashlight, for broken studs or visible black soot.

2




Evaluate condition of the nuts and bolts around the manifolds and the exhaust Y pipe, looking for rust. Spray all nuts and studs on the manifolds with a penetrating oil lubricant, such WD40.

3

Gather all of the tools and parts you will need to finalize the project so you dont need to worry about going out to get a tool or part once your Ford F150 is torn apart.

Preparation

4

Jack up the front of the Ford F150 onto jack stands.

5




Remove the wheel on the side where the manifold is leaking, using a socket and ratchet.

6




Remove plastic wheel wells, using ratchets and a pry bar.

Removal

7

Remove the four exhaust nuts that connect the Y pipe to the exhaust manifolds. Depending on the level of rust degradation on the nuts, it might be necessary to use extractor sockets to remove.

8

Remove the exhaust gas recirculation, or EGR, tube if you working on the left side of the manifold. Typically it will be so rusted you will need to cut the tube, using the metal hacksaw, as close to the manifold as possible. Otherwise skip to the next step.

9

Remove the all eight nuts from the exhaust manifold. When removing, dont be surprised if the stud turns and is removed with the nut or breaks off as you turn. Typically, the back nuts are the ones that will break off due to rust and fatigue. Then, remove any remaining exhaust studs that did not come off with the nuts.

10

Remove the exhaust manifold and discard the gasket.

11

Remove any broken studs by attempting to turn with extractor bits and a ratchet. If you are unable to extract, use the 90-degree drill, perably with counter-clockwise drill bits to assist in removal of studs, drilling a hole into the center of the stud, which might release it. Increase drill bit size, as necessary, to remove. Once the layer of rust on the stud is removed from the seat of the hole in the engine head, the stud will freely turn out.

EGR

12

Remove the top portion of the EGR tube from the EGR valve with a wrench, if you are working on the left manifold.

13

Replace the manifold if the EGR tube and nipple are so heavily rusted that you cant remove them.

14

Access the amount of rust and wear on the exhaust manifold. Replace if there is heavy rust build up on the face or clean by using the drill grinder.

Installation

15

Install new EGR tube and nipple if you are working on the left manifold.

16

Position new manifolds in place, over the gaskets, while lightly turning in the studs by hand.

17

Tighten the nuts top to bottom, right to left. In other words: tighten the top right, then the bottom right; tight the second from the right on the top followed by the second on the right bottom, and so on. Always start from the side closest to the back side of the engine.

18

Put the Y pipe back in place and tighten the bolts.

19

Reconnect the EGR valve to the exhaust manifold upper fitting.

Dual exhaust systems let your engine run cooler, decreasing the inherent back pressure and increasing horsepower for better performance. As the exhaust exits the car more freely, you will notice faster acceleration, stronger passing power and a terrific sound. As long as the muffler and pipes in the exhaust system are installed properly, your car will almost feel brand new.

Instructions

1

Select parts that are sized properly for your car. Higher-quality exhaust systems take advantage of mandrel-bent pipes and mimic the look of the original car parts. Your local auto shop may build custom dual exhaust systems, but they are probably created with generic parts and fit poorly.

2

Pick a kit that includes all clamps, hangers and hardware, so you will not be searching for pieces to complete the installation.

3

Stop blowing gaskets by using a steel donut gasket when connecting the manifold. The steel resists heat better than other gaskets, while sealing the pipe and manifold together.

4

Position exhaust pipes to clear both the floorpan and the driveshaft by at least 1 inch. When finalizing the setting, remember that the shaft moves up and down with rear axle, and the pipes must clear it completely.

5

Use factory muffler positioning to make most exhaust systems a simple bolt-on installation. If you place your muffler differently, the pipes may need to be bent accordingly. Hanging mufflers higher may require you to drill into the floorpan to hang them.

6

Mount tailpipe hangers near the frame rail to prevent the pipes from noticeably rattling. Brackets should face the front of the car in most cases. Your exhaust kit should come with the proper hangers, but you may have to have a few self-tapping bolts on hand.

7

Check the clearance before completely tightening all bolts. Things move as you attach other parts, so make sure there is still a 1-inch clearance. Rotate the rear axle to make sure the driveshaft doesnt rub against the muffler.

Adding exhaust headers may be the single easiest accessory you can add to improve engine performance. When working with modified cars and motorcycles, you may find that no company manufactures a header for your vehicle. With a few parts, you can build your own exhaust headers for your project.

Instructions

1

Take stock of what is already in your car. The exhaust header depends on your transmission, body type (or what different pieces make up your cars body), input shafts and suspension among other things.

2

Explore the interior of your car before you start. Installing headers require quite a bit of engine disassembly for most models. You certainly dont want to get your engine out with no idea how to put it all back together again.

3

Buy header kits that contain all the parts you need to custom build headers for your exhaust system. Most kits include properly bent U-bends and J-bends, collectors, reducers, straight tubing, O2 bungs and flanges. Each piece needs to fit your cars build. Each kit fits your cylinder head.

4

Save some time welding with a partially assembled header. Have the tubes shipped tacked to the flanges, so you can finish the welding yourself. This allows for last-minute customization without building the entire header from scratch. To save more time, choose kits or parts with tubes partially welded in place.

5

Look for quality materials when choosing pipes, collectors and flanges to avoid warping and excess movement. When using older car parts, try to find pieces that are not misshapen or rusted in any way.

6

Create the desired balance between performance and looks. Custom headers add a unique dimension to hot rods and racecars. Lake pipes, which run alongside the car, are popular choices to add show appeal.

7

Grind the welds smooth for a polished finish and the best performance. This often ends up being the most time-consuming part of the project, so you may want to decide just how much time you want to spend trying to create perfection. A racecar will need smoother heads than a show car that is rarely driven fast.

Engines transform air/fuel mixtures into combustion, creating horsepower. Engine combustion creates exhaust gasses that must be expelled from the combustion chamber in order to keep the air/fuel mixture clean. Intake systems improve combustion, while exhaust systems relieve an engine of waste gasses.

Air Intake Components & Function

Combustion is a mixture of fuel and air. While engines inject fuel drawn from a fuel tank, the air is pulled from outside through the intake system. Air is drawn through an intake tube and into a filter-protected air box. From there the air is driven into the combustion chamber.

Exhaust System Components & Function

Exhaust gasses exit the combustion chamber through an exhaust manifold that is secured to the engines cylinder heads. Exhaust then travels through a front pipe and into a catalytic converter, which filters harmful chemicals such as carbon monoxide. The cleaner exhaust finally travels through the muffler and out the tailpipe.

Performance Benefits

Upgrading intake and the exhaust system benefits engine-based performance. Aftermarket exhaust systems are designed to optimize exhaust flow and velocity while reducing back-pressure. This is accomplished through a change in piping diameter. An upgraded intake pulls increased air more directly through the filter. Both upgrades improve horsepower and fuel efficiency while increasing engine sound.

If there is ever a strong smell of engine exhaust in the vehicle, it means there is an exhaust leak somewhere toward the front side of the vehicle. It is imperative to have the exhaust fixed immediately as engine exhaust contains carbon monoxide, which will poison you. If the vehicle must be driven, drive with all windows down and the heating/air conditioning turned off to limit your exposure to the noxious fumes. There are several places exhaust fumes could leak from that would find their way into the cabin.

Exhaust Manifolds

With the engine running, check the exhaust manifolds for any leaks (remember exhaust is very hot and will burn you so do not touch it until the engine has completely cooled). Potentially, there could be leaks between the exhaust manifold and the cylinder head, or the exhaust manifold and the exhaust down pipe. If leaks are found, replace the leaking gasket. Inspect the exhaust manifold for extreme corrosion; in rare cases, exhaust manifolds have been known to corrode and may need to be replaced altogether.

EGR Valve

The exhaust gas recirculation valve directs exhaust back into the intake manifold. If the EGR valve gasket has failed, it will begin to leak exhaust gas, which may find its way into the cabin. Check around the EGR valve for any gasket leak, as well as the piping leading to the EGR valve for any corrosion or damage.

Catalytic Converter and Gasket

If the catalytic converter becomes plugged, it will create intense back pressure that can cause the mating gasket between the exhaust pipe and the catalytic converter to fail and leak exhaust fumes. Even from under the car, these noxious fumes can make their way into the vehicle cabin. Check for any exhaust leaks around the mounting point between the exhaust pipe and catalytic converter.

Leaking Exhaust Pipes

Over time, exhaust pipes can corrode and develop rust holes, especially in states that use salt for ice and snow control in the winter. Visually inspect all pipe from the engine back for any extreme corrosion or damage from other road conditions and replace as necessary.

In modern automobiles, the exhaust manifold is part of the larger manifold system. Its function is to remove engine exhaust--air and vapor, along with any uncombusted fuels--and inject it into the exhaust pipe to be carried out and away from the engine. A cracked or otherwise faulty exhaust manifold can result in inefficient fuel consumption and a pronounced drop in engine performance. It can allow harmful exhaust fumes to accumulate in the engine compartment, where they can then make their way into the cabin of the vehicle.

Pronounced Exhaust Odors

The most obvious sign of an exhaust system problem is the presence of exhaust odors in the passenger cabin, though this can also indicate a breach of the exhaust pipe beneath the car. To differentiate between the two, run the engine until its warm and open the hood. If there is a distinct smell of exhaust originating from the engine compartment, the problem is very likely in the manifold.

Performance and Noise Issues

Because combustion engines use the natural vacuum pressure caused by the compression, combustion and evacuation of air and fuel, another symptom of a cracked manifold is an obvious drop in engine performance. Weak acceleration accompanied by a stuttering effect may indicate a manifold problem, but it does not necessarily mean the manifold is cracked.

This obvious loss of performance accompanied by louder engine noise points more definitively toward a breach in the exhaust manifold. The noise will typically manifest as a louder exhaust rumble, or a wide-open sound. Again, a breach in the exhaust pipe may also cause this, so be sure to check under the hood while the engine is being accelerated to ensure that the noise is coming from the engine compartment rather than beneath the car.

Identifying Cracks in an Exhaust Manifold

A cracked exhaust manifold is not always immediately apparent. Stress fractures caused by excessive heat can start small and widen over time, making the effect difficult to notice until the engines performance is noticeably diminished.

Because most fractures are caused by heat stress, cracks will form where the heat is most concentrated, in this case where the manifold joins the engine. In older manifolds made of cast iron, cracks are usually harder to see, as rust accumulates rather quickly. In newer engines with aluminum manifolds, cracks may be more readily apparent thanks to aluminums lighter color and resistance to oxidation. Removal of the exhaust manifold and a close physical inspection may be necessary to locate cracks.

When subjected to the repeating heating cycle of your vehicles exhaust system, copper gaskets do not become brittle like standard paper exhaust gaskets. This extra durability allows copper gaskets to outlast other types of exhaust gaskets, reducing the amount of time you need to spend repairing exhaust-gasket leaks. Copper gaskets do require special sealants to ensure that the copper gasket seals your exhaust. High-temperature, copper-impregnated silicone sealants will expand and contract with the copper exhaust gasket and remain durable for the life of the gasket.

Instructions

1

Remove the old gasket material from both sides of the exhaust youll be connecting with the copper gasket with the 2-inch metal scraper.

2

Wipe both sides of the scraped exhaust connection with the clean rag to remove loose debris from the surfaces of the exhaust connection.

3

Set the copper gasket on top of the worktable and inspect the gasket to ensure that the gasket is flat.

4

Tap the high spots of the copper gasket lightly with the rubber mallet to straighten the gasket, if necessary.

5

Open the squeeze tube of copper silicone sealant by puncturing the foil covering the end of the squeeze tube with the top of the tubes cap.

6

Run continuous beads of the copper embedded silicone around each opening in the exhaust connection.

7

Gently place the copper gasket on one side of the exhaust connection and then place the other side of the exhaust connection against the copper gasket.

8

Reconnect the exhaust system per your specific situation while keeping the copper gasket in place.

The Dodge Ram Sport is a full-sized pickup truck made by Chrysler. The 1999 model year represented the end of the second generation for the Dodge Ram Sport. Like all trucks, the Ram takes a lot of abuse due to the design and intended use of the truck. One of the components that will eventually need servicing is the exhaust system. The stock exhaust on a 1999 Dodge Ram Sport will need to be removed if you want to upgrade it to a stainless steel exhaust. However, many people remove the exhaust to replace it because of corrosion or damage caused by road salt.

Instructions

1

Place a jack stand under the exhaust piping at various intervals to support the exhaust while you remove it.

2

Unbolt the exhaust to manifold bolts located at the front of the exhaust system. You may need to use an extended handle on the socket wrench, called a "breaker bar," to apply additional leverage on the bolts to remove them.

3

Disconnect the electrical wiring on the O2 sensors on the exhaust. These are plug-style connectors that pull right off.

4

Separate the exhaust piping from the manifold. It should pull right apart, but depending on where you live and the condition of the piping, you may need to pry the joint apart with a large flat-tip screwdriver.

5

Slide the exhaust piping and muffler off the rubber exhaust hangers on the underbody of the Dodge and drop the exhaust down gently onto the ground.

Exhaust hangers can vary depending on the year of the car. Make sure you purchase the right part for your year and model. To determine if your exhaust hangers need to be replaced, look to see if there are any cracks or tears in the rubber. Cracks and tears will allow the bracket attached to the muffler and muffler pipe to wobble back and forth. This can create additional noise from metal hitting metal and weaken your exhaust system due to excessive movement.

Instructions

1

Place a car jack under the designated area where the manufacturer recommends lifting the car. You can find this in the owners manual generally located in the glove box. Jack the car to a level you feel comfortable with to be able to move around under the car.

2

Place a jack stand under the frame of the car. Lower the jack so the car frame rests completely on the jack stand. If you need more than one jack stand, repeat Steps 1 and 2. Note: It is recommended to leave the jack in an area that will support the car (with little pressure on it) in case a jack stand gives way. By doing this, you will have extra protection keeping the car from crushing you.

3

Place your choice of ground cover under the car so you are not working on a dirty floor.

4

Position the exhaust hanger bolt hole to match the position of the bolt hole located on the frame of the car. Screw in the bolt and tighten until secure with either the correct size wrench or socket. Note: Depending on the year of the car, the exhaust hanger could have one or two bolts.

5

Slide the support bracket attached to the muffler or muffler pipe into the exhaust hanger. Make sure the support bracket is secure in the exhaust hanger. Repeat this step for all exhaust hangers.

6

Remove the ground cover. Repeat Step 1 by raising the car with the jack and then remove the jack stand. Lower the jack and remove so the car is now resting on the ground.