My head is spinning...What to do about exhaust manifold leak?

[RockyRider]

There are countless threads on this issue spanning well over a hundred pages. Most of them just document the back and forth *****ing between us about the issue. So since this is a known problem, that's been around for awhile, what are the options for getting this fixed?

I've already called one of the independent shops here in Central Oregon and was quoted $1,600 to get the manifold fixed, ouch! If the other side decides to go after I get the drivers side fixed, then I'm going to have to kill myself. Driving the 4Runner around right now is embarrassing and it's only getting worse. :toilet:

//UPDATE//

In my pursuit to find the best prices, below are some of the shops I've contacted.

ToyoTechs, the best Toyota shop in Atlanta has much better pricing. Unfortunately I now live in Central Oregon and prices are a lot more steep here.

ToyoTechs (ToyoTechs - Atlanta Toyota and Lexus Auto Repair, Service and Maintenance)
$900 to $1000 to replace one header.

//UPDATE 2//

I went to Good Guys Muffler and they did an outstanding job and I feel they did not charge me enough. I cannot say enough good things about the work they performed.

Good Guys Muffler (Bend Or) http://www.yelp.com/biz/good-guys-exhaust-service-bend
$850 - Both Sides!

Import Performance (Import Performance)
$1,600 to replace one header.

Toyota Of Bend (Kendall Toyota of Bend | Toyota Dealer | Serving Bend, Prineville, & Madras, OR)
$2,500 to replace both headers with OEM parts.

Custom Exhaust Specialist (Custom Exhaust Specialties - Welcome!)
$2,200/$2,500 to replace both headers using aftermarket parts.

Toy Doctor (Portland OR) http://www.toydoctor.net/
$2,700.00 Toyota Parts.

Specialty Automotive Service & Repair (Bend Or) http://www.centraloregonautorepair.com/
$2130 - One side

 

[JimInTN]

http://www.toyota-4runner.org/4th-g...t-4th-gen-v8-4-7-doug-thorley-headers-11.html

 

[SSt4r]

That above or replace with the factory ones hat might crack again sometime. Maybe you could have new ones beefed up before install where they crack? Some have used manifolds by Pacesetter but not sure how they've help up

 

[groverdill]

I am right there with you, while mine isn't terrible yet it bothers the hell out of me. I have no emissions testing so I may do headers but at the same time I have no welding experience for the cats.

What I want is a complete v8 headers to tailpipe kit, I can dream..

 

[t-man]

What I want is a complete v8 headers to tailpipe kit, I can dream..

This is what I am doing. A shop will install my headers and then build me true dual exhaust from the headers back for $600 including muffler.

 

[TOY2G]

This is what I am doing. A shop will install my headers and then build me true dual exhaust from the headers back for $600 including muffler.

$600, the labor to remove both headers should be more than that. Great deal

 

[t-man]

$600, the labor to remove both headers should be more than that. Great deal

It's 14.5 hours for headers installation, so up to $1100 for my mechanic. $600 is the exhaust piping from the headers all the way out with a muffler that will act as my h-pipe. So $1700 labor, $750 for the headers, $2450 total. Still cheaper than stock, and much better, and custom bent to keep it out of danger offroad.

 

[RockyRider]

ToyoTechs, the best Toyota shop in Atlanta has much better pricing. Unfortunately I now live in Central Oregon and prices are a lot more steep here.

ToyoTechs (ToyoTechs - Atlanta Toyota and Lexus Auto Repair, Service and Maintenance)
$900 to $1000 to replace one header.

Import Performance (Import Performance)
$1,600 to replace one header.

Toyota Of Bend (Kendall Toyota of Bend | Toyota Dealer | Serving Bend, Prineville, & Madras, OR)
$2,500 to replace both headers with OEM parts.

Custom Exhaust Specialist (Custom Exhaust Specialties - Welcome!)
$2,200/$2,500 to replace both headers using aftermarket parts.

Based on Toyotechs numbers it it possible to find a shop that will do the repair for under a grand. This is such a stupid repair, exhaust manifolds should not go bad unless it's a poor design, cheap quality part or both. I've driven cars with almost 300,000 miles on them that never had the exhaust manifold leak.

 

[t-man]

ToyoTechs, the best Toyota shop in Atlanta has much better pricing. Unfortunately I now live in Central Oregon and prices are a lot more steep here.

ToyoTechs (ToyoTechs - Atlanta Toyota and Lexus Auto Repair, Service and Maintenance)
$900 to $1000 to replace one header.

Import Performance (Import Performance)
$1,600 to replace one header.

Toyota Of Bend (Kendall Toyota of Bend | Toyota Dealer | Serving Bend, Prineville, & Madras, OR)
$2,500 to replace both headers with OEM parts.

Custom Exhaust Specialist (Custom Exhaust Specialties - Welcome!)
$2,200/$2,500 to replace both headers using aftermarket parts.

Based on Toyotechs numbers it it possible to find a shop that will do the repair for under a grand. This is such a stupid repair, exhaust manifolds should not go bad unless it's a poor design, cheap quality part or both. I've driven cars with almost 300,000 miles on them that never had the exhaust manifold leak.

What the hell are they charging per hour! The book calls for 7 hours per side for a total of 14 Hours. My place is charging me $1100, less if they can do it quicker. That's $75/hour. Several others have posted on here it cost them $800-$1000.

 

[LobstaMobsta]

this job actually books at 12 hours…I've done it in less than 6 hours more than once

 

[RockyRider]

this job actually books at 12 hours…I've done it in less than 6 hours more than once

Do you know if any shop guides exist that show step by step what needs to be removed to get to the manifold?

At these prices I'm considering doing it myself! A Toyota technical manual for this repair would be nice to see.

 

[t-man]

Do you know if any shop guides exist that show step by step what needs to be removed to get to the manifold?

At these prices I'm considering doing it myself! A Toyota technical manual for this repair would be nice to see.

What's hard is that they are so cramped in there behind the strut tower that there isn't much room to work on them. Also, iron bolts in an aluminum head make it so much more difficult as you get that whole "dissimilar metal stick." I usually do my own work, but I'm terrified of breaking a bolt off in the head and trying to figure out how to fix that. I imagine pulling the head would be entailed at that point as there just isn't any room in there. After you get the old stuff unbolted you have to cut the exhaust pipe in front of the cat, or make a y pipe if removing cats like me, pull out old manifold, install headers and weld them to your existing pipe. You will have to move the oil dipstick tube around during removal and installation on the passenger side, but other than that I couldn't see anything else in the way.
I have the service manual, let me see what it says for the manifolds. I downloaded it from here but I know the link gets removed every so often.

 

[BlackWorksInc]

Stupid question... Where are they cracked? Usually I have seen on the forums that they crack along the top where the flange meets the tubes. It's tight, but perhaps an experienced TIG welder could seal it up for you? The flange and tubes should be steel since it's a Cat/header combo.

Edit-

I think I was looking at a different picture, seems like they crack at the tube where it mounts to the block; so repair still requires removal either way.

What the hell are they charging per hour! The book calls for 7 hours per side for a total of 14 Hours. My place is charging me $1100, less if they can do it quicker. That's $75/hour. Several others have posted on here it cost them $800-$1000.

Looks like some of those quotes are including parts, curious what the part's pricing is.

 

[t-man]

Stupid question... Where are they cracked? Usually I have seen on the forums that they crack along the top where the flange meets the tubes. It's tight, but perhaps an experienced TIG welder could seal it up for you? The flange and tubes should be steel since it's a Cat/header combo.

Edit-

I think I was looking at a different picture, seems like they crack at the tube where it mounts to the block; so repair still requires removal either way.



Looks like some of those quotes are including parts, curious what the part's pricing is.

Nope, up to $1100 for installation of the headers. Then it's $750 for the headers, $100 for muffler, and $509 for full dual exhaust. Expensive, but needed for me.

 

[MFreund]

What's hard is that they are so cramped in there behind the strut tower that there isn't much room to work on them. Also, iron bolts in an aluminum head make it so much more difficult as you get that whole "dissimilar metal stick." I usually do my own work, but I'm terrified of breaking a bolt off in the head and trying to figure out how to fix that. I imagine pulling the head would be entailed at that point as there just isn't any room in there. After you get the old stuff unbolted you have to cut the exhaust pipe in front of the cat, or make a y pipe if removing cats like me, pull out old manifold, install headers and weld them to your existing pipe. You will have to move the oil dipstick tube around during removal and installation on the passenger side, but other than that I couldn't see anything else in the way.
I have the service manual, let me see what it says for the manifolds. I downloaded it from here but I know the link gets removed every so often.

A trick for getting the bolt out after it breaks it to weld a nut to what is left of the stud with a mig welder. It even works for one that are broke off flush.

Chevrolet pickups are know for breaking heads off the bolts. Recovering Chevrolet owner here.

 

[zimm298]

Just had my drivers side one done 2 weeks ago. Dealership broke the bolts off, and shipped the car to a speed shop. They ate the cost! Not a joke. They ate the entire cost. Makes me curious as to the whole story, but the car's in one piece.

 

[RockyRider]

Just had my drivers side one done 2 weeks ago. Dealership broke the bolts off, and shipped the car to a speed shop. They ate the cost! Not a joke. They ate the entire cost. Makes me curious as to the whole story, but the car's in one piece.

That's my worst fear as well. If a bolt breaks inside the head removing it would be really tricky.

The idea of welding a nut to the broken bolt stud an an option I've never heard of, but I'll keep it in my bag of tricks.

 

[groverdill]

I live in a no smog area and I am considering by passing the AIS on the 05+ and getting in on the current GP for the DT 03-04 headers.


edit
I have a 05 SE 4.7 and I am 99% sure both sides are cracked.

 

[RockyRider]

I live in a no smog area and I am considering by passing the AIS on the 05+ and getting in on the current GP for the DT 03-04 headers.


edit
I have a 05 SE 4.7 and I am 99% sure both sides are cracked.

Can you share a link to the exhaust manifold you're referring to?

 

[groverdill]

There is currently a Group Purchase in flight for 03-04(4.7) Doug Thorley headers
[MENTION=43095]tollboothwilley[/MENTION] is the man running it, I would suggest PM'ing him