Up pipe leaks - Ford Powerstroke Diesel Forum
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  #1  
Old 09-06-2011, 09:20 AM
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Up pipe leaks

My e99 has black soot by the tops of the up pipes by the Y shaped thing. Ive found brass doughnuts to repair this leak.
My question is, where the exhaust manifold connects to the "bottom" of the up pipe on the pass side, has soot all over the back of the block coming from this connection. How do I repair this? Is it a gasket thats blown?
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Old 09-06-2011, 10:22 AM
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There is a fiber crush washer that has vibrated loose. Research up-pipe leak and bellowed up-pipes. You can replace the washers, but i highly recommend getting the bellowed up pipes as the stock ones have been warn down and new crush washers are a temporary solution only.

You will need an air hose, air ratchet and a small 3" cutting disk (even better if you have a worn down disc thats at 2"). I would remove the turbo and housing. Makes life MUCH easier.
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Old 09-06-2011, 10:45 AM
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I have looked up leaks due to the up pipes. The only bellowed pipes I found are for 99.5 & up.
Is this crush washer hard to change?
Why the cutoff wheel?
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Old 09-06-2011, 10:53 AM
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My apologies, i missed the e99 mention. You'll need to do some research on the best way to fix those crush washer as I'm not sure on the differences.

I used the cut off wheel to cut out the factory bolts on the bellow install. Much easier than trying to back them out.
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Old 09-06-2011, 11:01 AM
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I am guessing you are talking about an Early 99. For one there is no gasket or doughnut at the bottom of the up pipes where the up pipe connects to the manifold. At least the two engines sitting here in my shop don't have any gasket or doughnut there. Only gasket or doughnut is up at the Y connection of the Turbo. This is where the Up pipe connects to the Turbo. I had 200,000 before the up pipe started leaking on my truck. I repaired it with factory replacement parts from the dealer. If they lasted 200,000 miles from the factory. They should last another 200,000.

Good luck getting the bolts out. I would strongly suggest you soak them with penetrating oil for a couple days. Apply the oil daily for a couple days to eat up the rust and break them free. This will prevent the bolts from breaking when you try to take the up pipes off.

Where the Up pipes connect at the manifold the bolts are nut and bolt I suggest you just cut those with a cut off wheel. You can use new grade 8 bolts from the hardware store.

The whole job is not that hard. Just tight areas to work in.
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Old 09-06-2011, 11:13 AM
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Do you think maybe the bolts are just loose, causing the leak at the bottom then?
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Old 09-06-2011, 01:04 PM
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I think the black soot at the bottom is from being blown down from the up pipes leaking at the top where they connect at the Turbo Y connector.
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Old 09-06-2011, 02:53 PM
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Up pipe leaks-sd530300-1.jpg

Up pipe leaks-sd530303-1.jpg

Here is what I am talking about.
You still think its coming all the way down from the collector?
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Old 09-06-2011, 04:37 PM
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Those pictures almost make me think it is the manifolds leaking not the up pipes.

There is no gasket between the manifold and cylinder head and there is no gasket between the up pipe and manifold.

The only place there is any type of gasket is at the connection of the up pipes and the Y connector to the turbo.
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Old 09-06-2011, 04:49 PM
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that's unusual. it's possible that the up-pipe rusted away in that area. it's also just as likely the leak ruined the sealing surface on the exhaust manifold. there's one way to know, take the pipe off and inspect the manifold
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