She's a '95 PSD and my wife complains about exhaust fumes in the cab when she travels in it. Usually happens during decel. I'm sure it's in the down pipe that I'm leaking from. Any thoughts are welcome.

I have been under the truck (of course) and looked at the exhaust. Found several pin holes where the cat was taken out and a pipe welded in. Pretty shotty weld job. But I can't see that being the problem rolling down the Hwy at 80 and those holes being under the cab.

Now, is there an exhaust system kit that will replace everything from the manifolds/turbo and back? I'm not looking for extreme, but a little upgrade wouldn't hurt my feelings. Does the systems that say "turbo back" cover to the manifolds also?

I am thinking muffler free, how much gain? Other mods needed?

Thanks ahead of time.

 

No reason to replace manifolds if not broken. "Turbo back" replaces everything AFTER the turbo. Check the top of the up-pipes for soot around connection at collector.

 

Your up pipes are leaking.

 

I must have mis-phrased. I have no intentions of replacing the manifolds. Sorry for that. Just thinking of replacing all the pipes.
I figured it was the up pipes, of course the hardest to get to, but I was thinking while I was there go ahead and try to find an entire set and upgrade the system to a better down pipe also.
I hear just repairing this part of the system is about an 8 hour job, is that right?

Any suggestions as to an aftermarket kit, even just for the front half of the exhaust is always welcome.

Thanks for the replies

 

The only upgrade is bellowed up pipes, but to use those you would have to convert to a superduty set up.

Turbo pedistal, turbo, up pipes, Y pipe, manifold, add an intercooler, and down pipe...

Otherwise just replace the doughnuts if the pipes are still in good condition. If not replace the pipes and doughnuts.

 

Don't really want to go into that much just to upgrade a little.
Is there a gasket kit that includes all the gaskets and donuts instead of buying them all individually?

I'm sure that fixing the leaks would help greatly. The cat is already gone (welds are a source of several pin holes) but what gains would I get over no muffler compared to a muffler on an aftermarket system? Any suggestions to an exhaust would be welcome also

I've worked on PSD's that are work trucks but this is the first I have been able to play with. Of course, as everyone, I am on a budget right now.

Any free or cheap upgrades that I can do would be interesting also. I do plan on looking thru the forum some more when I get time.

 

The muffler is the biggest restriction in the system. People think its the cat, but on the PSD's its a high flow cat, all you get by removing it is more noise.

I didnt know they made a bellow kit for the OBS... but sit down...

Riffraff Diesel: International Bellowed Up-pipe Kit 94-Early 99

Here are the up pipe doughnuts you need...

Riffraff Diesel: Fel-Pro 8194 Up-pipe Gasket Set

Riffraff Diesel Performance Parts: Diesel Exhaust Parts | MBRP 3" Aluminized Downpipe | Diamond Eye 3" Aluminized Downpipe - Exhaust Accessories

Some other exhaust stuff...

 

I just changed the injectors and with the residual oil in the cylinders, I now see where all the exhaust leaks are. Time for a new exhaust!

There are at least 6 spots under the truck that has come from the oil in the exhaust. Of course, the biggest being the up pipes

I'm slowly getting her fixed back to normal

 

Getting ready to do the up pipes and it's the first time I'll be doing them on a powerstroke. Is there a donut gasket on both the upper and lower flanges of the up pipes? Do I need 4 donuts for both up pipes?

Considering I am going to bew there, might as well do both ends.

 

Top only.