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Cracked number 1 & 4 exhaust manifold

422hp944

422hp944

New member
Hi guys - Have a pretty nice crack on my exhaust manifold where the 1 and 4 manifold merge into one, it's practically 80% way round the diameter. Can these be welded sucessfully without it cracking again in the same spot? ....Cheers

John Daly.
 
Had the wastegate pipe welded (short pipe from manifold) and it was perfect. The guy who did it said they had used the wrong wire in the factory which created a brittle joint. It was already 18+years old though so I didn't feel the need to take it up with Porsche. Not heard of the manifolds cracking before but worth a shot at welding I would have thought, they are relatively easy to remove and worse case it will fail again. (provided it isnt in a section that is ceramic lined - then worse case would be bits of liner hitting the turbo) However I would have thought they are relatively easy and cheap to find second hand.
good luck
 
I had some welds added around the outer side of the flanges so that I could grind off the ugly fat original welds inside runners which looked like they did not help with the flow. No sign of failure so far on the welds of both Y sections.
 
John, can you get a few tacks on while its in situ, its easy to create a tiny mis-alignment with re-welding on the bench, which becomes a stress load when its refitted.
Have not welded the pre-turbo sections but did tig the down-pipe and 3" exhaust with no issues.
good luck
George

PS - Its the summer heat in Wicklow maybe, if anything like Fermanagh :)
 
I've not heard of any cracking before so it's quite unusual, however there are not many cars over this side of the pond making the amount of power and torque that your 2.8 engine provides.

It might be worth a quick question on Rennlist.

If you consider fitting an after market manifold, make sure it fits a RHD car as most are designed in the States for left hookers and don't have to worry about the steering shaft on that side of the engine.
 
Yes George...Were not used to anything above 17 degrees most of the time!
Unfortunately the crack wasn't visible until it was taken off the car...thanks for the tips though...Cheers

John Daly.
 
My friend with the 444hp 3.0 engine cracked his exhaust manifold at the exact same spot, and I saw another set cracked at the same place, so I wouldn't think it's particulary exceptional.... hmm in fact I'm going to have a look at mine tonight.
 
Thanks Paul...It's something that could get overlooked easily, I may just get a good used one and be done with it, funnily, When I done a bit of internet research the likes of Lindsey racing etc reckon its quite common for the manifolds on our turbo cars to crack? I personally have never heard they were a weak point and never heard it happen to my fellow 944 turbo drivers over here either....Cheers

John Daly
 
I've just had the compression fittings in the exhaust replaced on mine and the garage found the wastegate pipe cracked and got it welded too.

Looks better than new.

Edit - it was the wastegate pipe that cracked, not the wastegate itself, duh
 
My exhaust manfold cracked, I forget the location, at about 70k miles. Fitted a good used part. I suspect the collapsed engine mount contributed to the manifold failure. Might be worth checking your engine mounts too.
 
Early turbo manifolds cracked on No 1 exhaust, the factory then fitted an expansion joint to later ones, my 220 manifold has been welded in the past, i have a later style 1 & 4 manifold with expansion section to fit should it happen again.
 
Mine is the later type with expansion bellows and still cracked. Paul 290T mentioned what could have contributed to the manifold cracking, failed engine mounts...mine are shot also so thats more than likely the cause, they are being replaced asap. Thanks for all the response guys...Cheers

John Daly.
 
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