1 vs 2 piece exhaust manifolds - Dodge Cummins Diesel Forum
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post #1 of 12 (permalink) Old 02-20-2020, 03:19 PM Thread Starter
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1 vs 2 piece exhaust manifolds

My manifold is leaking and starting to warp at 183K. I'd like to replace it before a bolt breaks off in the head. 2 or 3 piece manifolds used to be the consensus on 12 valve heads because the warpage could break off the ears on the head. Obviously that's not an issue on a 3rd gen head. I'm looking at the 2 piece DPS manifold and the AFE bladerunner 1 piece as they're the most affordable. Opinions on the benefits of a 2 piece for a 3rd gen?


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post #2 of 12 (permalink) Old 02-20-2020, 07:56 PM
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no experience with a 2 piece but the AFE SS Bladerunner I have has been solid as far as I can tell. I did have a broken exhaust manifold bolt on the #6 cylinder, next to firewall. No idea if the mani had anything to do with it, I suspect bad shocks on a dirt mtn road and not going slow had things bouncing a bit more then they should have been.

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post #3 of 12 (permalink) Old 02-20-2020, 08:02 PM Thread Starter
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Quote:
Originally Posted by steve05ram360 View Post
no experience with a 2 piece but the AFE SS Bladerunner I have has been solid as far as I can tell. I did have a broken exhaust manifold bolt on the #6 cylinder, next to firewall. No idea if the mani had anything to do with it, I suspect bad shocks on a dirt mtn road and not going slow had things bouncing a bit more then they should have been.
Did you break the bolt with the AFE on or was that the previous manifold?

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post #4 of 12 (permalink) Old 02-20-2020, 09:13 PM
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it was with the afe and after 5 yrs of service... i have a thread where we discussed the bolt removal, pics r there and there was no manifold shrinkage. i have the SS one...

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 432k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #5 of 12 (permalink) Old 02-21-2020, 02:53 AM
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The oem manifold was shrinking on my 03 HO and KT Performance had the best price on a 2 piece. I gasket matched all ports including the outlet and turbine housing on my II PS and it lowered my egt about 100 degrees. Get one! Craig

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If you take something apart and put it back together often enough, you will end up with two of them!
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post #6 of 12 (permalink) Old 02-21-2020, 03:49 AM
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I put on a 2 piece BD and it's been great.

[URL=https://www.amazon.com/gp/product/B001DNRP7O/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1[/URL]

Factory manifold warped/shrunk and broke one bolt on #1. Taking it off, the other #1 bolt broke (it was bent). I farmed it out and the wrench that did the work broke off one more bolt in #6. Fortunately, they all came out easily after a little Kroil, some heat with a MAPP torch, and a left hand drill bit. I am so glad I let someone else tackle that job in their big heated shop.

We also had to replace the exhaust side turbo housing as it had a hairline small crack.

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post #7 of 12 (permalink) Old 02-21-2020, 08:07 AM
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2 piece manifold is a GREAT time to swap to 2nd gen design , good flow and get back the proper cummins sound that the 3rd gen manifold destroys .
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post #8 of 12 (permalink) Old 02-21-2020, 10:43 AM Thread Starter
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I'm worried mine are about to break since a few are visibly bent. I had a bolt break on my old 12valve and it took two days to get it out! I'm not really interested in the 2nd gen swap as I don't want to have to change a ton of stuff and my egts are never an issue in my usage.

I'm thinking I'll go for the 2 piece. Thanks for all of the replies!

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post #9 of 12 (permalink) Old 02-21-2020, 10:52 AM
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Even a new Cummins 3rd Gen exhaust manifold would work fine.
Cummins re-designed it a few times, adding material for greater durability.


There used to be tons of used aftermarket 2 piece 3rd Gen ex manifolds around as most guys go to a 2nd gen ex manifold when they go with a bigger turbo or twins.

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post #10 of 12 (permalink) Old 02-21-2020, 12:33 PM Thread Starter
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Heres another question- does anyone know if the Borg SXE-300 series turbos have any clearance issues with the 2 piece manifolds? The joint looks pretty hefty and like it might get in the way of a turbo in some situations.
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post #11 of 12 (permalink) Old 02-21-2020, 04:37 PM
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No clearance issues.

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post #12 of 12 (permalink) Old 03-22-2020, 05:49 PM Thread Starter
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ENded up going with the DPS 2 piece. It's a very very nice piece. Definitely high quality and given it's the cheapest aftermarket manifold out there (other than the knock off ebay ones), I feel like it's a steal. I used stainless studs and nuts from purediesel power and a sure glad I did. I don't see how you can get the turbo on and off separately and turbo plus manifold is so damn heavy, it would be a huge PITA to try and use traditional bolts! I soaked all the old bolts in aero kroil for a week and sure glad I did. No bolts broke but dang, they were really close and the #1 cylinder holes needed some thread repair the old manifold was so warped!

Didn't notice any driveability changes. My Egts are never an issue. Maybe a little better boost, and less noise now that there is no leak!

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2005 QCSB NV5600, SB OKHD, CFM+, Jake brake, Thuren springs/arms/king 2.5s, CAT UHE 416-1225, CTS2, Optimal Welding HPTuners, BBI stage 1, II BOP, DPS exhaust manifold
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