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Engine Discussion of preventative/corrective maintenance and other technical issues regarding your coach's engine.

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  #1  
Old 04-13-2008
Rob Robinson's Avatar
Rob Robinson Rob Robinson is offline
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Default Exhaust Manifold Repair 8V92

I've been meaning to put a few pictures of an exhaust manifold repair done by Randy Dupree last year but haven't gotten around to until now. His drivers side manifold developed a leak due to gasket failure (see pics with screwdriver pointer) and upon removing the manifold it was discovered that the gases had burned a hole in the manifold face. Since the hole wasn't too deep he took the manifold to a buddies machine shop and had the face dressed up. Much cheaper solution. To gain access he loosened and slid the hydraulic reservoir down and removed some of the cooling system plumbing. At this time it was noted that the exhaust elbow coming out of the turbo had rusted through on the bottom so it was removed for repair. This made access even easier. One thing to be careful about though is the new gasket placement. There are indents it must rest in to seat properly. Be sure the gasket stays in place while re-installing manifold. If it doesn't and you tighten down the manifold it will crush and you'll be headed back to DD for a new one.
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Last edited by Rob Robinson; 04-13-2008 at 08:19 AM. Reason: Omitted a picture
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Old 04-13-2008
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one thing rob did not mention was i replaced all the studs and nuts that hold the manifold on,i got them at the detroit dealer,along with the gasket.
Randy
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2000 LXI 43
Bainbridge,Ga.
Port St Joe Fl.
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Old 04-13-2008
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Before doing my left manifold last year, I had the new one Jet Hot Coated. Should last
longer(if that's possible) and it's way cooler(temp) than the right one.

Steve Gureasko
90WB40 Jus Chillin
Ponchatoula, La.
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  #4  
Old 04-13-2008
jwasnewski jwasnewski is offline
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Quote:
Originally Posted by Randy Dupree View Post
one thing rob did not mention was i replaced all the studs and nuts that hold the manifold on,i got them at the detroit dealer,along with the gasket.
Randy
Just curious, does your coach have exhaust blankets?
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Old 04-13-2008
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nope,no blankets on my coach.
Randy
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Old 04-13-2008
jwasnewski jwasnewski is offline
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Thank you, I was just wondering why the pipe rusted through near the pyro probe connection. Trying to learn something for a change. lol
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Old 04-13-2008
BCRoamer BCRoamer is offline
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Default 8V92 Ehaust Issues

Had and in-chasiss rebuilt done at ~85k miles. Had to replace both exhaust manifolds, both heads and a lot of other parts. DD in Auburn, GA did the work, about $13k total. Whole thing started with a burned exhaust valve on right bank? Cause? Not sure but in my ignorance I think I overused the "start booster" trying to get it going in sub-freezing temps. Replaced the turbo-charger in Anchorage.

Part of the rebuilt was the 8V92 "hot rod" kit. This realy improved performance off the line, also had the ADEC reprogramed to use 1st gear in reverse. Had a real problem backing up the hill in our former home.

On our way to Alaska had to stop in Salt Lake to replace the muffler and the exhaust pipe right at the turn going up thru the roof. Burned a 5" diameter hole right through.

Coach runs great, just needs to be run. Problem with most of our coaches is that we just don't run them enough. Engine's been running great now. Went to Alaska with 4 newer Prevosts (60 series) and out-ran them on hills and off the line. Not bad for an old Bird.

Doing a big-screen HDTV installation right now. New MotoSat 5 LNB antenna, 32" Sharp 1080P TV and DirctDV's new DVR unit. Everything fits right in like it belongs there. I'll post some pixs in the next few days.

I do not have exhaust blankets either. I don't think you need them.
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  #8  
Old 04-14-2008
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Leroy, take a look at the pipe,when you bend pipe the seam needs to be on the outside of the bend,the outside of the bend on my pipe just so happens to be on the bottom of the pipe.
the welded seam is the weakest point on the pipe,the thinest too.
combine the weld being on the bottom with the rain that has come down the exhaust stack and the acidic reaction that diesel exhaust has with water and you get a rusted out pipe.
what i should have done is to drill a small drain hole in the bend of the new pipe.
Randy
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Old 04-14-2008
jwasnewski jwasnewski is offline
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Thanks, I forgot your stack exits the roof. I was trying to determine how water got to it. On my side exit, there is one U pipe that takes a beating. The rest stays dry. I did drill a 1/8 inch hole in the bend of my roof exit genset pipe to keep that from happening.
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Old 04-14-2008
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Quote:
Originally Posted by jwasnewski View Post
Thank you, I was just wondering why the pipe rusted through near the pyro probe connection. Trying to learn something for a change. lol
Good question Leroy. My pipe developed holes just like Randy's. I'm not positive but I believe that the bottom of the pipe might have rusted out from rain water entering the stack. I think rain water and soot results in a bit of an acidic situation
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