Help Needed Exhaust / Turbo Leak?

[dennisj2003]

Exhaust Smell in Cab:
If an exhaust smell is present in the cab, inspect for leaks at the exhaust manifolds. Ford's procedure calls for warming up the truck to operating temperature, then shutting off the engine, remove the EBP sensor and use a smoke machine to feed smoke into the exhaust system. Inspect each exhaust port, manifold flange and Y-pipe joint for smoke leakage. I find using a length of hose as a stethyscope while the engine is running works well to pinpoint exhaust leaks. If a leak is found at the exhaust manifold, replace only the manifold gasket that is leaking(I think this should read INSTALL a gasket, since originally there are no gaskets at the manifolds). Gasket P/N 5C4Z-9448-A.
TSB 05-13-9.

 

[fordoor]

Exhaust Smell in Cab:
If an exhaust smell is present in the cab, inspect for leaks at the exhaust manifolds. Ford's procedure calls for warming up the truck to operating temperature, then shutting off the engine, remove the EBP sensor and use a smoke machine to feed smoke into the exhaust system. Inspect each exhaust port, manifold flange and Y-pipe joint for smoke leakage. I find using a length of hose as a stethyscope while the engine is running works well to pinpoint exhaust leaks. If a leak is found at the exhaust manifold, replace only the manifold gasket that is leaking(I think this should read INSTALL a gasket, since originally there are no gaskets at the manifolds). Gasket P/N 5C4Z-9448-A.
TSB 05-13-9.

Anyone know how to make a homemade smoke feeding device for this procedure? I'm really needing to do this and don't want to pay a dealer for it.

 

[MONSTERPLOW]

Ford has a TSB on exaust leak at manifold, and recommends installing gaskets as a fix.
I cant remember but I think there is a 8 year 80.000 mile warranty on the exaust.

correct a mundo

 

[dennisj2003]

My way would be to have someone in the seat with the engine running, tranny in drive and power braking just a little, to get it to smoke good.
Make sure it is someone you trust in the seat, and dont stick your head under the fender well, may have to take inner fender out to see the manifolds.
I just seen this is a cali truck they not allowed to smoke,

 

[fordoor]

I discovered the exhaust leak - it was on the drivers side expansion 'joint' on the y-pipe. The woven stainless steel mesh was hiding a 1 inch burned out strip on a rib of the accordion expansion section.

The replacement y pipe was about $240 and NOT easy to get from Ford. If any of you know about a reasonable procedure to fix the old part or someone who is experienced in fixing these issues, I would like to know. In mid Sept, I am taking this project to a friend who is experienced with stainless steel but we are wondering if there are some new miracle coatings which may work? Or any other suggestions? Thanks : )

Let us know how this works out for you. I'm pretty certain I have the same problem. I'm still working on pinpointing it.