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Exhaust Leak

From 1993 Ford Bronco “Resurrected THRICE” — documented by Steve83.

13 photos
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1993 Ford Bronco - After driving it around for a week or so, an exhaust leak became apparent on the R side. I quickly eliminated the Y-pipe, 2ndry air crossov… 1993 Ford Bronco - With the Right wheelwell gone, it's easy to inspect the frame ground, just inboard of the spring tower on top of the frame rail. The batter… 1993 Ford Bronco - Looking rearward, the cowl drain can be inspected. This & the one on the driver's side often hold rotting leaves which can rust the body &… 1993 Ford Bronco - This is why I pulled the wheelwell; with it in-place, none of this is visible, and it's difficult to reach. The connector in the foreground… 1993 Ford Bronco - I wasn't able to get any penetrating oil on the tops of the flange studs before removing the wheelwell, but it'll be easy now. Surprisingly… 1993 Ford Bronco - This is what I spotted with the mirror & flashlight. These black streaks are only formed by exhaust leaks. The reason it occurred is that J… 1993 Ford Bronco - Note that the crappy exhaust manifold gasket didn't even touch half the lip of the manifold, which is why it blew out here. [url=https://ww… 1993 Ford Bronco - Most of the gasket material is gone, leaving only the rusty steel core. This is why gaskets should not be added - Ford designed the manifol… 1993 Ford Bronco - This shows the true extent of the problem caused by the gaskets. Notice the #4 port to the Left - it also has soot spots appearing on the h… 1993 Ford Bronco - To extract the broken bolt, I used a Snap-On A80A stud remover/installer. Afterward, I chased all the threads with a rethreading kit & thre… 1993 Ford Bronco - Because both the manifold & the head were still relatively true & UN-rusted, I used the same sealant as the factory - chassis grease in a t… 1993 Ford Bronco - Because both the manifold & the head were still relatively true & UN-rusted, I used the same sealant as the factory - chassis grease in a t… 1993 Ford Bronco - After letting it warm up slowly at idle & most of the oil had burned off, I raised it to ~2KRPM for a few minutes, which got the manifolds…