QSM11 exhaust gasket and cooler service

[Ryan Balsinger]

Well upon finding an exhaust leak a few trips ago, I finally took Tony’s advice and dove in.  After removing the coolant and raw water from the system, I removed the cross pipes from both the raw and coolant sides, and the transmission cooler from the back of the heat exchanger.  Removing the heat exchanger bolts leaving one in the top and side mounts as it is a little bulky and heavy.  Once those were free I removed the cooler, Note to have help as it is heavy and bulky!!  I then removed the aftercooler mounting bolts again leaving a couple to hold it in place for removal.  The aftercooler is much heavier then the heat exchanger so be sure to have help!!!

Well after all of the cooling system was removed, I removed the heat shield bolts from the manifold side of the heat blanket and CAREFULLY removed the hose clamp style clamps on the turbo side.  These get pretty hot and distort so be Patient.  After all the the shields were removed I soaked all of the manifold bolts with Blaster liberally and let sit overnight.  Then next morning I began removing the manifold bolts after removing the turbo.  Only to find that the awesome mechanics who were called to perform the same procedure failed to learn what grease is for!!!UGH!!!

THIS IS WHERE THE ART OF HAVING PATIENCE STARTED TO COME INTO PLAY!!!

I managed to remove all but 1 of the manifold bolts with the 1 breaking off with about an inch exposed.  Which I spent several hours and heat etc…  to try and remove, only to break it off flush.  I then with much patience I was able to drill out the old bolt and retap to clean old threads and bolt ran in nice and tight.  

I then proceeded to disassemble the cooler and heat exchanger at my shop/barn so I had a nice bench to work on, where I found the heat exchanger bolts to be either totally stripped or ended up breaking.  After breaking or drilling out 12 of the 44 bolts that hold it together, I managed(with much time and patience) to drill out and tap all of the existing holes without having to helicoil etc..

I then headed to the aftercooler which I figured would be much easier as it is just air and water…  Boy did I have that backwards!!  Again I assume no grease was used previously and 2 of the housing bolts just broke immediately upon trying to remove them.  Again after many hours and a few choice words and again PATIENCE I was able to drill and tap all of the holes back to original thread.  Of course this was after I had to drill 5 out of the 6 core bolts(due to them being extremely rusted and unable to extract) again I managed to drill and retap those with success again loads of patience and many hours!!

Now that I have everything disassembled and cleaned/degreased I am wire brushing the housings and painted parts for a fresh cote of paint.  I am also awaiting replacement parts from Seaboard who have been amazing through the whole process with the info online and on the phone.  Thanks again Gentlemen

 

Pictures to come shortly as well as reassembly 

Topic

[Tim Connolly]

More pics and assembly experience?

Hi Ryan,

I have the same engines and am having difficulty getting time on my mechanic’s schedule so TOYING with taking this job on with a good mechanical friend.  Was wondering how the rest of your experience went as well as reassembly tips and pics.

 

Thanks a ton for sharing what you have already posted.

Tim

PS – did you have any trouble getting parts?  one local Cummins shop said it was 18 months to get a new exhaust manifold.  Maybe Tony could comment.

[Rob Schepis]

DIY to the Max

Nicely done and thanks for posting.  Could not imagine how this would have gone if you hired it out.  I know for sure you would have had many MORE hours of downtime and many MORE choice words.

[Tony Athens]

Dealing w/ a QSM Dry Manifold & Aftercooler

An incredible amount of work here. You do have an amazing amount of patience and  “never give up” fortitude.

Keep this pics coming

What is your GPH at 1800 & 2000 RPM? 

Outside mechanics?–Good luck

[Ryan Balsinger]

Photos

Here are some of the photos 

[Author]

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