So my 1992 RS 3.1L has a nasty exhaust leak on both manifolds. I was told by a mechanic that some of the bolts that hold the manifold on have broken (he said it was common for that design) and that he would have to drill them out and put new ones in. He also said he would have to resurface the manifolds. After all that, he said its best to take the manifold gasket out and weld the manifold on. He estimated it would cost around $400-$500....Does all of this make sense and is the price reasonable? I've experienced almost every car problem there is except exhaust, so I need help. Thanks.

 

Why not just put a new high quality gasket back on?

I don't see why he would want to weld them on there, seems like a bad idea to me.

 

If the bolts are broke flush then yes drilling them is the best way and sometimes you can drill a small hole and then use an extractor. Heat can be used but an experienced person should only do this. Resurfacing is standard procedure but welding them back on is down right stupid and impossible especially if the head is aluminum and the manifolds are cast. A good gasket should seal it back up no problem. How many bolts are broke?? I'm a tech and this is a time consuming and tedious task which is not fun. The price sounds reasonable and 75% of that is labor.

 

I believe he said just two were broken on one side and one on the other.. Its gotten a good bit worse since then though.. He said that most of the gaskets don't seal correctly because of all the extreme heating and cooling that goes on right there, and the best thing to do is just weld them straight on..unless I misunderstood him..

 

Unless you misunderstood.

Is it possible that your mechanic is trying to tell you he has to weld the leaks, then put the manifolds back on with new gaskets?

That's the only sensible thing to do with headers.

For that amount of money, resurfacing included, wouldn't you be better of getting a set of good used or even new headers for the car?

http://www.summitracing.com/parts/RNB-674-704/

 

No the manifold isn't cracked or anything. And I have read several other forums where they put the manifold back on without the gasket.. and I'm gonna be paying pretty much the same to get the bolts and everything replaced, so if I get new manifolds, I'm gonna be out an extra $150-$200..

 

For 4 to 500 dollars you coold get a decent set of headers. Why waste money on stock manifold.

 

Yeah but what i'm getting done is basically just fixing the bolts that hold the manifold on and having my manifold welded back on... So If I bought headers, i'd have to pay all the money for them plus the same amount to get those bolts and everything fixed.... 4-500 just seems a little high just to tap out those bolts..