zerowkul98
New member
Anyone know the root-cause of this? Design flaw? Lack of proper maintenance? Etc etc?
Exhaust manifold leak/tick
- Thread starter hamiltonj2w1
- Start date
Ducman
New member
Its a design flaw. The welds at flange on the header are prone to failure. To further complicate things you cant see the spot where the weld fails until you remove the headers (which on our trucks is a pretty big PITA).
There is usually a hairline gap where the flange meets the pipe right where they bolt up to the head.
To further add insult to injury nobody makes an aftermarket header for a 2005 V8 4runner so we are stuck with Toyota ones which cost an arm and a leg.
Fun fun, I'm saving my pennies to afford a replacement for mine at the moment...
the dutch man
New member
Anyone have a cost to remove the manifolds, weld them, and re-install with new gaskets? That is likely going to be the way to go here.
Ducman
New member
Although Im sure it could be welded I think it would be really tough. The surface where its welded cannot protrude out or the header wont fit so I think it would have to be welded and then ground down and there really isnt much material there. And if you warped the flange you'd have a leak caused by that too...
Here is a closeup of where the leaks normally happen.
I have an 04 V8 that has started this noise when you start it, then it quiets down as it gets warmer, sounds like an old lifter tick. I was afraid of something like this, as mine is at 145K miles, and I am sure the dealer will smile and wave at me when I ask for it to be serviced under a TSB.
pretty sad failure, nothing with exhaust is fun to work on.
pretty sad failure, nothing with exhaust is fun to work on.
the dutch man
New member
Ducman,
Great pic. I was wondering where the crack was and to my surprise, that is a real bear of a spot to weld. I'm wondering if it is even worth fixing on my 03. I'm hoping to keep it for another 2 years and get something newer. I definately will not spend $3K on this fix. Not worth it.....
Great pic. I was wondering where the crack was and to my surprise, that is a real bear of a spot to weld. I'm wondering if it is even worth fixing on my 03. I'm hoping to keep it for another 2 years and get something newer. I definately will not spend $3K on this fix. Not worth it.....
Ducman
New member
Yeah well the Manifold runs about $600 plus the gasket and probably new bolts so probably close to $700 total. Plus a Saturday of your time and some skinned knuckles :redbrick:
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hamiltonj2w1
New member
My dealer said they will weld it but won't replace the manifold because the TSB is only for the V6 but according to this info I should have some ammo for them to replace them instead of welding them.
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Ridger
New member
Crap... mine just started doing this 2 weeks ago. I feared this was the case. We had it at the dealer and my wife asked them about it and they said they suspected it was a cracked manifold and told her it was a $1,500 job (roughly). Mine has 120,520km's (74,890 miles). I can't stand that ticking sound.
Man I still owe over $400 on that last service from 2 weeks ago (rotors and ceased brake caliper).
Man I still owe over $400 on that last service from 2 weeks ago (rotors and ceased brake caliper).
inscarguy
Member
this is covered under warranty!!!!!!!!!!!!!!!!!!!!
if you complain about the sulfur smell which has a TSB (and it is for ALL 03-09 4runners). on the V8's the manifold and cats are one piece cannot be bought seperately. if you still have an Emissions warranty or its Toyota Certified then you WILL get it done for FREE!
i complained at about 65000 miles about the sulfur smell and the tick(i had cracked manifolds) and they confirmed that by another V8 4runner in the shop.
when all said and done i got a brand new factory exhaust from and including the manifolds to the muffler. no more tick and no more smell. been this way for over 18000 miles.
trust me i went though it.
if you complain about the sulfur smell which has a TSB (and it is for ALL 03-09 4runners). on the V8's the manifold and cats are one piece cannot be bought seperately. if you still have an Emissions warranty or its Toyota Certified then you WILL get it done for FREE!
i complained at about 65000 miles about the sulfur smell and the tick(i had cracked manifolds) and they confirmed that by another V8 4runner in the shop.
when all said and done i got a brand new factory exhaust from and including the manifolds to the muffler. no more tick and no more smell. been this way for over 18000 miles.
trust me i went though it.
stanleybb50
New member
Are you sure they change manifolds with the sulfur tsb? Or did they change yours because you mentioned the tick? I just got the sulfur tsb done yesterday and the manifold looks original on my v8 after install.
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inscarguy
Member
yes they were changed because they are 1 piece. my new ones look old also but the heat shields were perfect. i made sure they were changed because i asked to see them when they were removed. the rt was cracked at the lower flange and the left was cracked at the flange that bolts to the engine.
when i brought it in i complained about the tick and the sulfur smell. when i picked up the vehicle both problems were fixed by changing the manifolds due to the cats and manifolds being one piece. so i killed two birds w/ one stone.
i have the invoice to prove it. i also checked in my toyota database i have on my laptop and it confirms they are 1 piece.
like i said before if you still have the emissions warranty or the certified warranty(i had both at the time) they will get done for free.
when i brought it in i complained about the tick and the sulfur smell. when i picked up the vehicle both problems were fixed by changing the manifolds due to the cats and manifolds being one piece. so i killed two birds w/ one stone.
i have the invoice to prove it. i also checked in my toyota database i have on my laptop and it confirms they are 1 piece.
like i said before if you still have the emissions warranty or the certified warranty(i had both at the time) they will get done for free.
stanleybb50
New member
Excellent to hear! I didn't have the tick or anything yet on my '06 v8, but due to the sulfur tsb being done now, its great to hear I stopped the tick before it could even start.
Thanks!
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SMEE
New member
Toyota database on your laptop? How do I get one of those? By the way, taking in my 4R tomorrow morning to get the TSB sulfur problem fixed (under warranty).
SMEE
New member
Manifold/Catalytic Converter one piece?
Please select a corresponding number from the illustration below to view the details of that part.
1) Exhaust manifold Left 2) Gasket Gasket Either Side 3) Stud Upper Either Side
4) Nut Nut Either Side 5) Manifold cover Left 6) Bolt Bolt Either Side
7) Converter and pipe Right 8) Converter and pipe Right 9) Heat shield Upper
10) Heat shield Lower 11) Heat shield Holder 12) Clamp
13) Muffler and pipe 14) Resonator and pipe
According to Conicelli Parts Center Online, the parts mentioned in the TSB- 17410-50450 and 17450-50121 which are the front pipe assemblies 1 & 2, will be replaced. The diagram implies that the replacement parts will just bolt up to the manifold, and are not including the manifold. I looked under my 4R and sure enough, the cats bolt up right behind the manifold. They are not one piece. Please tell me I'm wrong.
Please select a corresponding number from the illustration below to view the details of that part.
1) Exhaust manifold Left 2) Gasket Gasket Either Side 3) Stud Upper Either Side
4) Nut Nut Either Side 5) Manifold cover Left 6) Bolt Bolt Either Side
7) Converter and pipe Right 8) Converter and pipe Right 9) Heat shield Upper
10) Heat shield Lower 11) Heat shield Holder 12) Clamp
13) Muffler and pipe 14) Resonator and pipe
According to Conicelli Parts Center Online, the parts mentioned in the TSB- 17410-50450 and 17450-50121 which are the front pipe assemblies 1 & 2, will be replaced. The diagram implies that the replacement parts will just bolt up to the manifold, and are not including the manifold. I looked under my 4R and sure enough, the cats bolt up right behind the manifold. They are not one piece. Please tell me I'm wrong.
