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BRAD
Dodge Dakota
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9/23/2004
18:02:59

Subject: Exhaust Manifold swap?? 99 to 92/93
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I've got a '99 Dak 4X4 with a 3.9. One of my exhaust manifold bolts has broke off and now is leaking. It'll cost me $200 to have the manifold removed, resurfaced and reinstalled plus getting the bolt tapped.

A while back I thought I read a thread about installing a set of exhaust manifolds off a 92/93 3.9L to obtain an additional 10HP. I can't find the thread now, but was wondering if the HP gain is real and if I would switch manifolds if my current Y pipe will bolt up or if I'll need a new Y pipe too?

If it makes sense to get my exhaust problem fixed and the possibility of adding more HP it only would make sense to just do that.

Then again, would it be better to just add headers? To many options and I don't want to throw a lot of money at this.

Thanks for your input.

Brad





gen1dak
Dodge Dakota
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9/23/2004
22:05:46

RE: Exhaust Manifold swap?? 99 to 92/93
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The '92 and early '93's do flow better thanks to a larger inside diameter, and offer better hp, 10-15, depending on V6 or V8. A matching y-pipe is required. Due to the rarity, and overall cost, headers would be only moderately more costly, but much easier to obtain.



Jay Wingate
Dodge Dakota
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9/24/2004
23:47:15

RE: Exhaust Manifold swap?? 99 to 92/93
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There may be a broken header bolt causing the leak. They're fun to remove.



Wadak
GenIII
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9/25/2004
17:18:48

RE: Exhaust Manifold swap?? 99 to 92/93
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Post on 92 and 93 exhaust manifolds:

http://www.dodgedakota.net/boards/v6/6918.html

Just cut and paste into you browser.



Wadak
GenIII
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9/25/2004
22:36:01

RE: Exhaust Manifold swap?? 99 to 92/93
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Brad, I happen to have a pair of 92 exhaust manifolds, I picked up at a junk yard, I was going to put these on my truck till I came across a good deal on a set of jba headers on my 97 v6 dakota.

I measured the 92 exhaust manifolds vs. the 97 exhaust manifold with a digital micrometer.
92 ex. 97 ex

Inside diameter 2.14" 1.90"

Exhaust manifold 3.6" 3.6"
flange bolt center
to center






Wadak
GenIII
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9/26/2004
01:52:52

RE: Exhaust Manifold swap?? 99 to 92/93
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Brad:

Check out this link on ebay a pair of 93 v6 dakota manifolds:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=7924491681&category=33632



BRAD
Dodge Dakota
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9/26/2004
21:37:43

RE: Exhaust Manifold swap?? 99 to 92/93
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Thanks for the info. guys.

So, if I'm able to obtain the manifolds will my current Y pipe work with the older manifolds?

Wadak, what would you like for your manifolds?

Thanks,
Brad



Wadak
GenIII
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9/26/2004
22:06:18

RE: Exhaust Manifold swap?? 99 to 92/93
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I dont want to sell mine set, I keep them as a back up in case, I have problems with my headers. I believe the older manifolds bolt right up.



Wadak
GenIII
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9/26/2004
22:16:05

RE: Exhaust Manifold swap?? 99 to 92/93
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Brad,

Check out car-part.com for the manifolds.



JFH
GenII
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9/28/2004
09:34:36

RE: Exhaust Manifold swap?? 99 to 92/93
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The 92/93 Engines have an EGR, the manifolds won't work on non-EGR motors, AKA all Gen III's

http://www.cardomain.com/memberpage/546400

gen1dak
Dodge Dakota
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9/28/2004
18:16:28

RE: Exhaust Manifold swap?? 99 to 92/93
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Hey JFH?
Ever heard of BOP?
Block Off Plate.
Problem solved.



J and J Auto
GenII
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9/28/2004
22:15:41

RE: Exhaust Manifold swap?? 99 to 92/93
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All manifold geomotry is the same just the 92-93
exhaust manifolds were bigger and flowed better

The Y-Pipe location was the same 92 to 03 3.9

Larry
J&J Auto

BRAD
Dodge Dakota
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9/28/2004
23:17:57

RE: Exhaust Manifold swap?? 99 to 92/93
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Thanks Larry for the confirmation that I'll be able to use my current Y pipe.

Larry or Gen1Dak,
I don't know anything about EGR/non-EGR...What is this BOP and purpose? Will I need one if I want to put on the older manifolds??

Where can I obtain a BOP, if needed?

Thanks,
Brad



gen1dak
Dodge Dakota
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9/28/2004
23:45:03

RE: Exhaust Manifold swap?? 99 to 92/93
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Brad, sorry, but "BOP" was just my play on "JFH". If you go around asking for a "BOP" they're gonna think you're nuts. Anyway, the solution is real. A block-off plate can be fashioned with a little piece of thick sheet metal from the hardware store cut with tin snips. Add some high-temperature gasket material (think header gasket) from the auto parts place, bolt it down and you're done. EGR was used in the pre-OBD (before 1996) engines. Exhaust Gas Recirculation was used to reduce NOx emissions by diluting air/fuel mixtures by adding some exhaust gas (under normal driving conditions...wide-open throttle was not affected). The EGR tube ran from the passenger-side exhaust to the rear of the intake manifold. Since your intake has no opening for the tube, that's okay, but you will need to close off the exhaust hole where the tube ties in.



BRAD
Dodge Dakota
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9/29/2004
08:59:26

RE: Exhaust Manifold swap?? 99 to 92/93
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Gen1dak,

This went from a simple swap to a little bit of fabrication. It sounds like I'm using this BOP as a gasket then correct?

If I read your response correctly I need the sheet metal AND and header gasket, correct? How thick do I want this sheet metal and gasket to be?

Do I use the header gasket as a template for the sheetmetal?

I think my current manifolds bolt directly to the heads without any gaskets. What's the purpose of adding gaskets with these earlier manifolds?

What can I use to plug the ERG tube at the manifold?

Thanks,
Brad



gen1dak
Dodge Dakota
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9/29/2004
21:12:18

RE: Exhaust Manifold swap?? 99 to 92/93
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You intake manifold has no place for the EGR tube to attach. There's no hole there, so there's nothing to cover. Removing the EGR tube from the exhaust manifold leaves a single opening about the size of a nickel (approximately). The sheetmetal needs to be 14-18 gauge. The piece you cut out will be larger, and oval-shaped. Once you have the manifold, it'll make more sense. Your current manifolds use gaskets to seal to the block, you just can't see them. This gasket material will make a leak-free seal under the sheetmetal plate. The shape of the gasket is basically just donut-like. You only need a small piece of gasket material for this. Pretty much any available thickness will do. Once the EGR tube is removed, you need not worry about plugging it (just the hole in the exhaust). If you know anyone who welds, there's always that way of sealing it as well. You might also be able to tap the opening and plug it with a short, threaded plug. I did this once with a Mopar 2.2 intake and exhaust. It's really not nearly as bad as it sounds.



colton
Dodge Dakota
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12/20/2012
12:58:23

RE: Exhaust Manifold swap?? 99 to 92/93
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Will that change gas mileage?



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