I have a Fleetwood Bounder 39R with Cummins 330hp Turbo diesel. Noticed that the Exhaust manifold was cracked and needs replacement. This is apparently a common problem with Cummins Engines. Ordered the parts from Cummins in Spartanburg SC for $ 369.00 including Gaskets and Bolts and received them the next day. Excellent Price and Service. At that time I ask how much Cummins would charge to install the manifold and after checking with Service, I was told that the installation alone would be $ 1,600.00 not including parts. Good thing I was sitting down.! The Engine sits approx. 12 inches below the large opening in the Bedroom and the Exhaust manifold is clear from obstructions and easily accessible from this opening. The mechanic working on that Engine could even run the AC in the Motorhome to be very comfortable. Based on experience this work should take about 4 hrs at the most since there are only 16 bolts involved including the Turbo charger. This means the Cummins charges $ 100.00 per bolt. !!! Guess I will do the Job myself as planed.

Let us know how that works out. Best of luck!

If I were doing that work, Murphy's law would apply. Every bolt would probably break or not come off, I would drop the turbo charger, the gasket would get mangled up, I would scrap every last bit of skin off my knuckles and they would have sent me the wrong parts.I would gladly pay a mechanic $1,600 to do that work.Teddy, you have a talent that I did not get and I admire people who can do that type of work.Good luck,MM.

By the way... this job is on my short list of things to do and, as such, I have a price from a Freightliner shop to do the job for considerably less... I think it's between $1200 and $1300, parts included. I remember the mechanic telling me that, yes, this is common on the Cummins ISL, also common is for one or more bolts to sheer off. So... be careful bragging about how easy it will be. Just like, invariably, when I comment about how a particular freeway is moving along here in Southern California, I find a jam just around the corner. :W

I have very little experience with diesel engines, so excuse me if it's a stupid question. If a cracked exhaust manifold is common on Cummins engines, wouldn't it be wise look into a Banks or other aftermarket exhaust manifold that does not tend to crack?

I try to stay away from brand name, company owned or franchised, shops. You are paying a big hourly rate for the name on the billboard out front and not the mechanic who does the work. I find that the little locally owned diesel shops have some very excellent mechanics, and I don't have to pay the big time hourly rate. They perform just like the big boys in the city at almost $40 less per hour. And they work as well, if not better, than those big boys.But I do admire that guys who can do that kind of work. It takes a special person. Plus I do not like black grease under my finger nails. Doing a job like that takes me forever, because of all the hand washing I have to do.

How much???? | Good Sam Community

32 Replies

kdk
Explorer
Aug 16, 2013
As mentioned before, be generous with the Kroil and with the time to let it soak in. I had mine replaced at Cummins repair facility under the original manufacturer warranty. They quoted 6 hours but turned out to be 17 hours of labor due to 10 broken bolts that were drilled out. That was 3 yrs ago and made sure they used anti-seize on the installation. I mentioned Kroil over PB Blaster as I have used it in industry with very good success.
Good Luck; Keith
path1
Explorer
Aug 16, 2013
Wow I had always wanted a diesel but now I'm not so sure. A known flaw that they refuse to correct. And just keep it running once you start it up in the morning. Fuel must be a lot cheaper than gas.
Not much stuff that doesn't have a weak point of some kind.
Stuck_in_first
Explorer
Aug 16, 2013
Wow I had always wanted a diesel but now I'm not so sure. A known flaw that they refuse to correct. And just keep it running once you start it up in the morning. Fuel must be a lot cheaper than gas.
JumboJet
Explorer
Aug 16, 2013
Install an Exhaust Gas Temperature gauge and shut the Cummins down once the EGT gets below 400F.
bob_b
Explorer
Aug 16, 2013
There are several potential problems resulting from a poorly designed exhaust manifold used on motor homes. The manifold on trucks is different and not interchangeable. The design to allow normal expansion and contraction from heating and cooling was flawed. The result is cracked manifolds, broken exhaust bolts, and cracked cylinder heads. You may encounter any combination of the three. The price you have been quoted, $1,600.00, seems a bit high. I had mine done at an independent shop for $1,000.00, which seemed high until I watched the technician bending over the motor under the bed drilling out broken bolts. It was very labor intensive with disastrous potential. Trying it yourself, you maybe lucky to find it is just a broken manifold. However, if you get stuck removing broken bolts your only option is to have the motor home towed to a shop. I am glad I paid to have it done professionally. Bob
PS There are aftermarket manifolds designed with a "slip" connection in the center that fix the design flaw
hipower
Explorer
Aug 16, 2013
With bolts like manifold bolts where they have been heat cycled thousands of times and are generally rusted somewhat, I have found the previously mentioned soaking to be required procedure and heating is a bonus for those with the equipment to do so. In addition I have had good results with actually tightening (even just slightly) the bolts prior to loosening them helps break them loose initially. If they are turning hard while removing it also helps to lube them again and turn them back in rather than trying to keep them coming out.

Exhaust manifold bolts are the most frequently broken ones and require a little extra effort and caution. That usually results in better success and less drilling of broken bolts.
falconman
Explorer
Aug 16, 2013
Since I may be in the market for a unit in the coming year, exactly how often is this occurring? Just started my research and its the first I've heard of the problem.
Mr_Mark1
Explorer
Aug 16, 2013
I have a question.... I have always let the engine run until the engine temp falls under 185 from the 199-205 temp that is normal..... so, how do you know you have a cracked manifold?

MM.
NMace
Explorer
Aug 16, 2013
Double post
NMace
Explorer
Aug 16, 2013
Ivylog wrote:
sailor_lou wrote:
The price seems excessive to me too, but then I do all my own work so I have no experience with shop charges. Soak the bolts for a few days with PB Blaster or better yet, Kroil before attempting to remove them.

X2 on the Kroil even putting some heat to the nuts and then soaking some more before trying to remove. If you break a bolt then having a shop do the work will start to look like a good idea.

They have it right.

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How much????

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