Help Needed Exhaust / Turbo Leak?

[MuleMan]

I am getting frustrated with an exhaust leak on the driver's side manifold vicinity. There is a hole tapped into the 'elbow' for the pyrometer thermo-coupler, which is tight but somewhere near this spot it continually blows fumes as there is exhaust soot and I can feel some hot air rushing out when it is running. Also, at idle it often sounds like an air compressor leaking and it makes a hissing sound that clicks on an off. It has been running warmer exhaust temps (7-900 degrees) without a load and the boost has been higher than normal (3 - 5). The EGR valve has been cleaned and that smoothed out the idle and quickened the response times. Logically, I know the approximate location of the leak however cannot really pinpoint it nor can I figure out the cause. How much exhaust back pressure should there be at this location?
I have mentally kicked around lots of possibilities but will take any advise any of you can provide of items to check.
Thanks and I look forward to your replys.

Vehicle specifics: 2003 XLT 6.0 4x4, 6 speed, 43,000 miles, Edge juice w/ attitude monitor, AirAid air filter, rotella synthetic oil.

 

[DaveBen]

Crawl underneath your truck and look for a cracked manifold. It does not happen often, but it does happen.

Dave

 

[fordoor]

MuleMan, Daves suggestion is the first place to look. Our rigs (at least the 03')do not have exhaust manifold gaskets from the factory, and may be leaking there. Anytime the manifolds need to be removed (like replacing headgaskets or a leak)then they get replaced w/new exhaust manifold gaskets. If that's not the source of the leak then it's probably the Exhaust Expansion Joints, or a possible cracked y-pipe. There are two expansion joints at the back of the engine (one for each exhaust manifold)that connect manifold exhaust to the y-pipe, and then to turbo. Be careful, the exhaust fumes can be sucked into the cab until you get it fixed, and more so when you use the vent fan. Suggestion: Park it up on ramps/blocks/or hoist at night and check first thing in the morning when it's stone cold. The dealers use some kind of smoke machine for locating hard to pinpoint leaks. They install at the EBP sensor location I think. Good Luck.

 

[no-red 6 0]

ditto that...as i HAD gaskets put on by ford 5 years ago when i was having issues

 

[MuleMan]

Thanks for the tips. I think several things are contributing to the leak. First off, the manifold doesn't appear cracked from all the angles I could inspect it from. This is what I have discovered so far - a burr on the manifold kept the thermo-coupler fitting from seating well, tightened the manifold about 1/4 turn on each bold, and snugged the expansion nuts about 1/2 turn. What I would like to do is yank the manifold, plug the old hole, machine in a new thermo-coupler port, and put a real exhaust manifold gasket on. Hopefully all this work will pay off. While I am in there, add a better breathing down-pipe? Thanks again for everyone's advise.

 

[strokepower]

While I am in there, add a better breathing down-pipe? Thanks again for everyone's advise.

might as well... it can't hurt

 

[MuleMan]

Exhaust Leak Found

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 : )

 

[strokepower]

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 : )

you talking bout the manifold crossover pipe? my brothers 05 just got back from ford with the same problem... his was under warrenty and it only took them a day to replace it... im sure they removed the cab??

 

[BamaSixGun]

I don't know of a repair that would fix it, may have to go ahead and bite the bullet and get a new one.

 

[dennisj2003]

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.