We've got a 1985 Ford 9000 with a DD 6V92. The exhaust riser pipes on both sides have cracked at the flanges. These connect the manifolds to the turbo base. The left side pipe cracked at the top flange, the right pipe cracked at the bottom manifold flange. Both pipes cracked in the last couple days while we were chopping hay. We brazed them last night, but we're not overly confident about brazing being a long term fix for them We called our local Detroit dealer and they said it's $800 for both pipes! For a truck that might see 400 hours in a busy year, where else is a good source for these pipes? Or a better long term repair to the existing pipes? I looked on eBay and found a used pair for $600 with $85 shipping so that's not happening. A couple other Detroit sites had them for $750 shipping so same as dealership. I'm considering taking to a muffler shop and seeing if they can cut out the thin, cracked area and weld on a new end piece, but at what cost and how long before the other flanges crack? We could end up have $800 into someone else repairing our old pipes if we aren't careful. Any other suggestions? Just looking at this from all angles before I drop big coin on 5ft of bent pipe
do you have access or can you tig weld? post some pictures of the cracks to see if they can be welded..
Someone should be able to fab them reasonably cheap
Not knowing just what they look like, could you just make flanges out of some 3/8-1/2 plate and weld in the correct size piece of, say, schedule 40 black iron pipe? As you say nit may see less than 400 hours a year it should not be too hard to fab-up something that will work.
The first 2 is the where the RH riser pipe meets the manifold. It was cracked 3/4 of the way around. We removed and brazed it and it seems to have held well after 4 hours of run time this morning. I guess we will see if that's sufficient to get us through long term or not. The last picture is where the LH pipe meets the turbine collector. It's a tiny crack that wasn't causing the excessive noise that the RH riser pipe was making. Now that we're done chopping, we will pull it and repair it before it gets any worse.
It used to be in the Walker Heavy Duty exhaust catalogs they listed various sizes of "marmon flange" adaptors that would slip over the old pipe after you cut an inch or so off the old pipe, then you could lap weld the stub to your existing pipe. Fixed quite a few 8V-71 end dump manifold connections that way.
Now that I see the type of connection I agree a good truck shop should have an exhaust catalog with parts in it you could use to replace the bad end like RZ suggests. Check out this link if it works: https://www.donaldson.com/content/d...America/F110028-ENG/Exhaust-Product-Guide.pdf Scroll down to about page 32 or 33 for some ideas.