Exhaust Leaks

[Broompilot]

Being a little bit of an expert on this.

The Cummins ISC has a poorly designed exhaust manifold that it is one piece. Brand new this truck got a crack and almost killed me in my forth month of service when the APU had failed and I idled the truck to keep warm. Heacache, upset stomach WOW I was very sick. No noise just the killer gas and I could smell it after I woke up.

This was late March, no realizing I had a leak I just thought it was from idleing it and being a rookie did not have the info to know what was going on. The summer months kept the engine metal from contracting and expanding as much. Come November it was fumes + noise. Repaired under warranty.

Now one year forward, the injectors failed and with trying everything under the sun to figure out why a Dyno was performed. The stress caused the mishap to happen again. This time you'd a thought I was riding a harley with straight pipes and the gas appeared again. My dealer wanted me OUT OF THERE after over two weeks they were more eager for me to get back to work than I was. But after getting the trucks injectors all set and returned from Cummins with now another broken exhaust manifold and no parts for at least another day.

My dealers Service Manager called me into a short meeting and explained "I cannot stop you but I do not want you taking this truck until we fix this". After my earlier expierence my life was just little more important than the next run I would miss. They did give me a giant break on replacing the manifold, and I figure this will probably be an on going repair for this engine. So it goes.

The problem being compared to Cats, is this a one piece manifold with all that heat and expanding and contracting its gona crack plain and simple. Cats are designed in smaller pieces so not as much of the stress on a large piece of metal but either three or six different mini manifolds leading into the exhaust pipe.

If you have a Cummins ISC and you hear anything odd from the engine especially during acceleration HAVE IT CHECKED.. The repair should be around $700 and maybee less at a local shop.

I wonder how rich my wife would be if I would not have woken up that Saturday in Seattle? She is stuck with me now.

 

[greg334]

Broom,
I just posted a reply on the other related post - Hope all owner's are not like this - and should have added this.

First the problem is also with 12 valve and early 24 valve ISBs. I have replaced all the manifolds on all my dodge trucks at one time. I know that there are after market manifolds that are three pieces, but maybe Cummins got around to change the design.

But here is what I should have added this to the other post;

There is more to an exhaust leak on a truck than just some a funny smell. Even though it may seem trivial, some of these trucks like the FL-70 and M2 are not made for OTR and don’t have the safety features like the class 8 trucks. One safety feature that I understand is in all the trucks (according to FL engineers) made for the last 5 years is when you use the recycle feature in the HAVC system, it is timed to go back to drawing fresh air into the cab to prevent CO2 poisoning while idling.

And CO2 detectors are not 100% effective when idling. CO2 detectors detect CO2 but do not detect other things that will make you sick.

Take leaks seriously.

 

[simon says]

Thanks for the info. Mine is a 2004 model spec and have had no problems. One injector was replaced early on, but I will keep an eye on this. Usually, it seems the problem with an engine comes early (like the old CAPS fuel pump), and if not experienced, engine is o.k.
I am concerned a little bit about the horizontal muffler/vertical exhaust system on mine. If I developed a leak in the horizontal, it could come up into sleeper. I rarely idle truck for long periods, but certainly a concern. The difference with a Diesel is one will smell the fumes and realize the problem- propane will just kill you!

I was parked next to some Rumble Trucking expedite who had a belly exhaust under a small sleeper one day last Sat. in Bolingbrook. He was running the truck all night and day. In the a.m. I had to move away: he was killing me.

 

[LDB]

I just bought a Kidde brand unit that is a combination of smoke and carbon monoxide alarm. The model is KN-COSM-B and it was under $40 including the first set of batteries.

Leo Bricker, 73's K5LDB, OOIDA Life Member 677319
Owner, Panther trucks 5508, 5509, 5641
Highway Watch Participant, Truckerbuddy
EO Forum Moderator
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Support the entire Constitution, not just the parts you like.

 

[greg334]

Leo,

Thanks for the brand and model number.

I am not saying not to get a CO2 detector; it should be standard equipment for everyone in every truck.

What I am saying is if you have a leak, CO2 is one the most prevalent thing that will get most sick but there are other things in the exhaust fumes that can make people very sick and a CO2 detector will not detect them. One thing is some of the chemicals used in the fuel additive that are harmful and some can have a reaction to a chemical, even with a very small quantity - some what like a peanut allergy where people who are in smelling range of a peanut product have reactions.

Oh before I forget, I wonder what the life expectancy is for a CO2 detector. Seeing that they are in a truck and trucks are not known for their boulevard ride, I would guess the life of the detector would be cut short and need to be replace on a regular basis. I know that smoke detectors, both commercial and home models have a specific life to them and they should be replaced. I replace mine every 4 to 5 years regardless.

 

[x06col]

Keep stay'in at the truck stops, and you'll keep lov'in it ya know. Keep ideling and you'll still love it. It's March and you have to idle?? I'm confused???

 

[x06col]

I'm sorry, forgot. Make sur you go DIRECTLY to the DOT when (if) you wake up, and see if there is a problem. Or, you can just carry a clamp "if" you know you have equipment with exhaust problems.