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modain
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11/12/2006
17:13:09

Subject: Exhaust Leak at Manifold
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OK, it's not my Dakota, It's my Durango. Same engine etc. :-)

I just isolated the under hood popping noise that started last Tuesday evening. Since then I let it sit until I figured out what the deal was. When it starts up the popping is real loud and then after a short warm up it's gone.

I suspected a leak at the manifold and I was right. In fact, the top bolt on the rear cylinder of the right side (either #7 or #8 - which side is odd, which side is even?) manifold is busted off at the bolt head. This bolt has an extension for the nut holding down the back end of the heat shield. It can now flap.

Question I have is how much of a bad thing is it to continue driving it in this condition? I know the leak will only get worse and eventually not seal. But could this cause the manifold or the exhaust port surface to get screwed up?

Also, how much time is involved with fixing this. How much ??? is a reasonable repair job going to cost if I had it done at a shop?

What's your left foot doing?
=========================================
2002 Graphite QC SLT Plus, 4.7L, NV3500, Superchips 3715, 3.92 LSD, loads o'fun...
2001 Patriot Blue Durango SLT, 4.7L, 45RFE, Superchips 3715, 3.55 Open (for now)
1999 Forest Green Dakota RC Sport, 2.5L, NV1500, 3.55 Open


Josh
Dodge Dakota
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11/12/2006
20:45:50

RE: Exhaust Leak at Manifold
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Even numbers on the right (passenger side).
Over time, there could eventually be cuts and erosion in the softer metal of the head due to hot exhaust gasses squirting through the leaks.
And If memory serves, there'a a kinda EGR port back there at cylinder 8 as part of the exhaust manifold.



OBIO3
Dodge Dakota
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11/12/2006
21:31:08

RE: Exhaust Leak at Manifold
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It's not a question of IT MIGHT eat a passage. If left long enough, it WILL eat a passage gouge in the engine. You sure don't want that to happen. Sujestion . Don't use OEM bolts to repair. You wil end up in the same boat again . Go with good quality bolts/studes to fix.

So many problems .... So little time



JHNSTREETS
Dodge Dakota
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11/13/2006
20:17:55

RE: Exhaust Leak at Manifold
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REPLACE IT OR HAVE IT WELDED BE SURE WHO EVER DOES IT DRILLS A HOLE ON EACH END OF THE CRACK TO STOP IT THEN WELD IT UP



modain
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11/13/2006
21:11:21

RE: Exhaust Leak at Manifold
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Thanks for the help guys.

Good quality bolt? Something like grade 8, etc?

I don't know where the last poster comes up with the idea my manifold is cracked. I'll check it when I take it off, though.

What's your left foot doing?
=========================================
2002 Graphite QC SLT Plus, 4.7L, NV3500, Superchips 3715, 3.92 LSD, loads o'fun...
2001 Patriot Blue Durango SLT, 4.7L, 45RFE, Superchips 3715, 3.55 Open (for now)
1999 Forest Green Dakota RC Sport, 2.5L, NV1500, 3.55 Open


paul
Dodge Dakota
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11/22/2006
00:16:08

RE: Exhaust Leak at Manifold
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I just had this subject on here a few months ago. it sounds like a bad lifter,but its not.the same problem I had with mine also.dodge covered it under warranty,on my 04 dak.actually they replaced both.I had about 34000 mi on it, and they replaced all.



daddio
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11/22/2006
15:23:48

RE: Exhaust Leak at Manifold
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maybe covered under the Fed emissions warranty? 8yr/80k.



OBIO3
Dodge Dakota
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11/23/2006
00:31:07

RE: Exhaust Leak at Manifold
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Yes, grade 8 is my choice. At the least, change all bolts/studs on that side. I would do both sides otherwise you will be drilling the other side as well. Save the pain. Keep in mine. One or more may be on the verge of breaking already and break as your taking them out. Better to chance that then be guarenteed you will be drilling later.

So many problems .... So little time



jayb
Dodge Dakota
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11/23/2006
03:43:36

RE: Exhaust Leak at Manifold
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when you do it, use a impact gun on low setting. ive noticed when using the rachet with socket, i break more of the exhaust bolts than with a gun, i guess the gun just shakes them loose at the same time that it pounds them off. just my experience on many vehicles speaking.



busterv
Dodge Dakota
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11/24/2006
02:24:11

leak on intake
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read a past post about a exhaust leak on the intake, my 2000 dak 4.7 makes a ticking noise when cold, after a short warm up it's gone. what am i looking at for repair cost?



Kyle Atkinson
Dodge Dakota
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2/25/2009
08:41:28

RE: Exhaust Leak at Manifold
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i just bought a 2006 V8 Dakota, started making a slight ticking noise on acceleration only in the cold. After a diagnoses at the Dodge Dealership they confirmed right (passenger side) crack in the exhaust manifold. They should have it fixed today, but I see that this is a common problem... Since it's being repaired under warrenty I doubt they will go with better bolts etc... The truck only has 31,000 miles on it.

Paul, How many miles do you have on your dakota now? I hope their fix lasts... I guess if it happens again I could find some headers to replace...?

Kyle



chrisiliohan
Dodge Dakota
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3/02/2009
19:25:37

RE: Exhaust Leak at Manifold
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I had the same stud broke. I removed the broken stud by welding on a stainless steel nut 3/8 just so I didn't have to deal with the plating.With the alum. block the nuts or weld won't bond. It took many attempts finaly turned out. I was about 4 hrs in total



ecdak
Dodge Dakota
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3/02/2009
23:49:27

RE: Exhaust Leak at Manifold
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I had the same exact problem with my dakota. When I first started it would rattle and what not. After a minute it would stop.



cb
Dodge Dakota
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3/22/2009
10:54:13

RE: Exhaust Leak at Manifold
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Ahh. Same problem on my 2002 Dakota v8 4.7. I havent had a chance to actually see the busted bolts, but the symptoms are all the same. Ticking when cold, goes away after heated up. Now, I would love to save money and do this myself, but is it a do-it-your-selfer project. I've drilled out busted bolts before from the exhaust manifold on my boat engine, but that was right there...easy access. What does it entail getting to the manifold on the dakota. Can I get to it from the wheel well. Can I do it without pulling the manifold off? It looks like it could be a real potential pain in the arse...If I cant, what am I looking at do you thing, cost wise, to get it done? ANy help would be appreciated. You know, with the weather getting warmer, it seems to be doing it less,and as it doesn't stop me from driving, I've been letting it go, but Im afraid of doing permanent damage if I let it go. is that the case? Thanks



nert
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4/23/2009
15:06:11

RE: Exhaust Leak at Manifold
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just a little advice from a vintage mechanic. Grade 8 bolts may have you going in the wrong direction. The grade 8 bolt won't expand enough and pop goes the fastener. Your better off with a 5 or less. back in the day i used to stack 5 lock washers on some known to blow international truck manifold bolts to allow for even greater expansion.

Anyone know what the exhaust stud size is for a 95' Dakota 4 cylinder?



miketarrant69
Dodge Dakota
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7/05/2009
08:16:50

RE: Exhaust Leak at Manifold
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My Dakota is a 2004 and this is a ongoing problem. Dodge has replaced them 2 times already ( manifold gaskets ) and guess what it is now off warranty and they need to be done again.  Just jack up the truck pull the wheels off, and the inner fender well. Then you can see right on in and giver. Shouldn't take too long, but yes use good bolts and I am looking for a really good gasket this time, not OEM. Mike



jeannie
Dodge Dakota
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3/01/2010
09:27:35

RE: Exhaust Leak at Manifold
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Time and cost



say what???
Dodge Dakota
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3/01/2010
13:47:56

RE: Exhaust Leak at Manifold
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jeannie WTF are you on?



William
Dodge Dakota
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7/27/2010
21:13:34

RE: Exhaust Leak at Manifold
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I have a 2001 2.5L Dakota. The rear stud is either missing (can it rattle out?) or broken. What size is the stud? What recommendations are there for replacing?



pssst
Dodge Dakota
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7/28/2010
15:23:47

RE: Exhaust Leak at Manifold
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William I'd look that over real good, It most likely
snapped off in the block and not came out.



Linda
Dodge Dakota
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8/19/2011
10:09:23

RE: Exhaust Leak at Manifold
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I think I may have this same manifold problem. While getting my oil changed, I was told I have a slight crack in the manifold. They tell me $1,000.00 to fix. Is that in fact true? Does anyone know where I can get that done cheaper??? Or is that not possible???



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