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Old 12-31-2013, 12:40 PM   #1
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Ford Lehman hole in exhaust manifold

1977 80hp hole in manifold just where the elbow flange connects to the manifold...1" x 1/2 inch ...1) can it be welded (caste) ? 2) I have the basic manual but no instructions on repair of dismantling. unlike a car there are cooling hoses and pipes from the tranny and oil coolers attached to the elbow and manifold and other sources. I assume this all has to come off?. no water leaks from the hole...only exhaust . Any ideas about removing bolts that have been there since 77?...any other advice is appreciated. pic attached
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Old 12-31-2013, 01:02 PM   #2
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Greetings,
Mt. T. NO PIC SEEN?????? In general, when dealing with nuts and bolts that have lived in the same place since '77, try soaking the offending fasteners with a good penetrating oil first (may take numerous applications over several days). I have had some success with one of these to encourage stubborn nuts...
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If all else fails, heat with a torch ONLY if you know what you're doing. If not, hire a professional.
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Old 12-31-2013, 01:05 PM   #3
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Thanks RT...what about gaskets? suppose I will have to cut new ones...
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Old 12-31-2013, 01:05 PM   #4
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Sounds like time for a total replacement and not a patch job. 37 years is pretty good for a marine elbow/manifold. Call up American Diesel and they can steer you towards a new elbow or manifold. While you're at it change out all the connection pipes and hoses too. There are several good yards nearby, you may want to get an estimate for the overall job. Removing some of the old bolts can be a chore unless you are skilled and able to do it, namely the rusted in place bolts that may well need easy outs and rethreading.
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Old 12-31-2013, 01:33 PM   #5
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Sunchaser...a new one is $1500 from Bomac...thats alot of diesel...actually its not a lot of diesel and thats the real crime here
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Old 12-31-2013, 01:50 PM   #6
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Two years ago I went to replace my elbow and found that the manifold had rusted thru I think where you are describing. It was not quite that large of a hole though.
I had to remove the manifold to get the bolts out (actually only one bolt)
To fix the end of the manifold I had a machine shop mill the surface until it cleaned up.
I think the shop charged me $50 for the work
There is a lot of material on that manifold, so see if you can find a automotive machine shop to do the job.
And you can get all thegaskets at adc.
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Old 12-31-2013, 02:00 PM   #7
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Greetings,
Mr. T. For the life of me, I can't see where the problem is with the manifold. The elbow looks "iffy" but the manifold looks OK. Old age, eyesight failing.....
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Old 12-31-2013, 02:17 PM   #8
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RT! good spotting! ya got me dead to rights...the pic is of my starboard engine manifold as an example of where it hurts...the actual damage is on the less accessable port engine manifold...of course!#@&* best view is this from overhead..upper right dark area and under hoseclamps is black residue blown thru by hole. you can see tranny cooler etc.
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Old 12-31-2013, 02:20 PM   #9
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even better..you can see the end of the manifold here and all the mess under it
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Old 12-31-2013, 03:28 PM   #10
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Soak the 4 bolts/nuts and tap them lightly over a period of several days then try them with a good fitting box wrench until you can work them loose. If they won't move more soaking and tapping. If still no go' heat as mentioned above.

Close the seacock and remove the exhaust hose & clamps and the saltwater hose & clamp.

It may turn out you just have a bad gasket but you can't tell w/o getting it opened up.
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Old 12-31-2013, 04:56 PM   #11
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Greetings,
Mr. T. I think Mr. Brooksie has nailed it-bad gasket. At least that's what my money is on until you start an autopsy. Not terribly likely the manifold is holed but anything is possible. Let's reserve judgement and hold off on ordering any gaskets until that sucker is laid open.....Both Bomac and AD should have gaskets on the shelf. Might have to install 2.
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Old 12-31-2013, 05:09 PM   #12
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Try to use a six point socket, not twelve point.

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Old 12-31-2013, 08:13 PM   #13
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bad gasket would be too easy..1/2" thick gasket? I can get my thumb in there...gaskets not that thick is it?...but hole does feel very square..curiouser...a rotted hole would be jagged ...I will party tonite and go to the boat tomorrow to check further and soak bolts with penetrating stuff..always good suggestions on the forums..thanks guys and Happy New Year!
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Old 12-31-2013, 08:55 PM   #14
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I bought elbows for my 120s from FredWarner1 on Ebay, worth a try, about $180 I think. Came with gaskets, certainly not 1/2" thick. Waiting for the elbows, I sealed the leaks with the 2 stick underwater setting epoxy putty. Story ends there, elbows were fitted by the mechanic as part of other work.
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Old 12-31-2013, 09:00 PM   #15
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Just had a quick look on Ebay..............
Ford Lehman 120 80 Exhaust Elbow 3" 1A372 FOR Marine Diesel Engine Manifold | eBay

Hope this helps...
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Old 12-31-2013, 09:05 PM   #16
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Quote:
Originally Posted by rochepoint View Post
Well spotted, that`s the guy, I would happily deal with him again..
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Old 12-31-2013, 09:50 PM   #17
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A cast iron manifold can be repaired by brazing, I've repaired many over the years. Not a job for a rookie but a experienced welder should have no problem.
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Old 12-31-2013, 11:56 PM   #18
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Tangler,

From your pictures this looks like the elbow. If so, I had a similar issue. The wet exhaust had eaten through the bottom of the elbow. I am a rank amateur, but was willing to try the replacement. The elbow cost me about $130. Hose pipe and fittings another $50. Time and fear I handled with tequila. Called the mechanic, almost brought him in because of lack of confidence on my part. I went forth and replaced the elbow and gasket.

Again IF it is just the elbow. You know better than I. Pictured is my old elbow looking similar to yours...
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Old 01-03-2014, 05:52 PM   #19
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looks about right...loosened the elbow flange bolts today to the point where water started to drip out...how much water can I expect? sea cock closed...cant see any anti siphoning device to stop any water coming back from outside..?? does the coolant need to be drained or is that a different system altogether? as you may have surmised I have never opened a marine exhaust system...
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Old 01-03-2014, 06:00 PM   #20
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Greetings,
Mr. T. Damn that memory. I forgot about the coolant escaping after the elbow is loosened. At least I think it should be coolant. Sorry.
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