Cracked Manifold

**Transporter** · 01-06-2011, 03:22 PM

Yep, the end of the crack needs to be drilled out on both CI or pressed steel to stop the crack from spreading, ...if someone attempt to weld it. With the TIG you can probably choose better suited metal for filling/joining the crack.

**Sunny43.5** · 01-06-2011, 09:39 PM

I thought we had a similar problem with our family ride T5 diesel , turns out due to bad fuel the bloody thing backfired and blew off the induction intake hose result clouds of acrid black diesel smoke from engine bay and out the back with loss of power . Over the next few hours and days refitted it many times until eventually the bugger would not clip back the retainer was worn to the point it would not hold . So being a bit of a bush mechanic I fitted a couple of screws to lock it in place has been perfect ever since Howard

**Umai Naa!!** · 01-06-2011, 11:30 PM

These manifolds pretty much break number 1 runner clean off the flange.

The replacement part has been revised, although only slightly.

It's quite an expensive job to carry out, as the manifold (and gaskets, fastners, etc) totals to around $1200, plus it's quite time-consuming due to the location of everything.

**tron** · 05-06-2011, 05:24 PM

Ta for all your replies all,
Still driving around but will hopefully get it done later this week...
Will be going down the welding route, so will keep all informed.
Thanks again

M

**Umai Naa!!** · 06-06-2011, 05:48 PM

You may need to have the flange faced, as it will most likely warp once it's welded.

**augie** · 19-07-2011, 05:39 PM

Had a go at welding up a cracked exhaust manifold today,got it from my local vw mechanic was off an 06 that they replaced at 110k was full of cracks, one flange was cracked half way around the turbo flange at the flex joint had a cracked 80% around right through the center of the weld and two that had started beside some welds.
It welded very nicely using the tig and 316 filler rod, got to hot when welding the turbo flange and melted a hole in the very thin flex joint steel so now it definatly is rubbish.
My local mech is saying spend the money get a new one, $1100 got a quote today from VW, I would much rather keep that money and try a welded one unless the new one has been improved to go alot longer than the 45k I got out of mine.

**Transporter** · 19-07-2011, 06:13 PM

Sorry to hear that it work well augie, at least you've tried. Maybe get a second one (cracked) and weld it slowly. Mine is still good at almost 90,000km.