Exhaust Manifold - Torque Sequence & Values ??

[daflentge]

FJ60 10/84 build date, Exh/Int manifold off the truck. I'm in the process of replacing stock isolator with a SOR SS isolator.

While doing that I've discovered that exhaust ports 4-5 are not flat - Shocked aren't you! I was to.

So, I'm in a pickle... no local machine shop (Western CO) will touch this FJ60 Exh/Int set-up (all the threads say machine as a complete assy only). I also don't want someone to 'practice' on my only set. The cost of shipping from here to Timbucktoo & back is also an issue... If I could even find a shop that has experience.

How about two gaskets! I have a stock already, what else to go with it, Felpro? I also thought about using Permatex Ultra Copper RTV on the stock gasket, but having mixed feelings now.

Here is where you all come in...

1. What approach is 2nd best - assuming I can't get the assy machined?

2. Anyone used Ultra Copper with success?

3. What is the torque sequence & values when I put the Exh/Int manifold back on?

Thanks in advance

PS: I looked into a new assy, $1000 from SOR - not in the budget.

 

[mwebfj60]

Just put a new gasket in tonight. Torque 29-36 ft-lb. Good Luck.

 

[antichrist]

with the SOR stainless isolator plate make sure that you more than adequately trim the start up diverter vane. the isolator plate WILL oil can (or buckle) and, if the vane is not trimmed enough, it'll bind, break and block exhaust flow. After experiencing such scenario, I have remove the vane. Not a problem in California. The western slope may not be so kind on cold winter days

 

[daflentge]

Curious about trimming start up vane... Instead of that, why not put a 1/2" or 3/4" hole or two in the Isolator Plate.

The holes should provide enough stress relief to keep the flat isolator plate from buckling don't you think.

Anyone else had the issue with the SOR plate buckling/oil canning?

 

[daflentge]

Torque Sequence

MWEB - thanks for the torque diagram.

That is exactly what I was not able to find in my previous searching on the site.

 

[daflentge]

Sorry antichrist - I just looked again at my exh manifold and now I understand what you mean. If I don't trim it, then it wll hit the SOR flat plate.

Thx - I'm a little slow in the morning.

 

[Gurr]

Get the manifold machined. Why go through all of that work and find out it leaks halfway down the road?

 

[rover67]

It took me forever to find a place that was willing to machine my manifold assembly here in the Denver area, but it was the only thing that fixed my leaks. I tried several gaskets.

FWIW, here's the place: Spit Fire Engine and Performance

I know it is very far from you.

After machining the OEM gasket, torque values, and sequence sealed it fine.

Find somebody that has a big belt sander and ask them to do it... most folks don't want to machine it on a mill since the cast iron exhaust manifold apparently tears up mills. At least that was what I was told.

 

[daflentge]

Rover - Thx for the tip... I'm calling them today.

Denver is not that far away.

 

[rover67]

Be warned, He sounded kind unhelpful on the phone... but in the end was a nice guy. Remind him all yo uneed is for it to be "belted".. he might even remember that he did one for me since it was only like a month or two ago.

also, it was $100 to do it I think. I think it was worth it even though it was much more expensive than I was expecting.

I work just down the street from him, so let me know if i can help in any way.

 

[Gurr]

Be warned, He sounded kind unhelpful on the phone... but in the end was a nice guy. Remind him all yo uneed is for it to be "belted".. he might even remember that he did one for me since it was only like a month or two ago.

also, it was $100 to do it I think. I think it was worth it even though it was much more expensive than I was expecting.

I work just down the street from him, so let me know if i can help in any way.

Wow, that is expensive...when I brought mine in(the second time) the guy quoted me half that. Then he gave me even more off because I paid him in cash.

 

[rover67]

Wow, that is expensive...when I brought mine in(the second time) the guy quoted me half that. Then he gave me even more off because I paid him in cash.

yup, it wasn't cheap, but it was all i could find. I called a ton of places.

 

[lehiguy]

Remflex gaskets. I never milled any of my 2F manifolds and I never had a leak using the old F gasket which Toyota no longer sells. The Remflex is the way to go, it can tolerate quite a bit variance.

 

[daflentge]

Exhaust Manifold - Flat & Installed

Rover - Thx for the tip... Spitfire did a nice job on the manifolds.

I ended up using one Toyota Gasket, and a couple of half washers as shims for the different height of the bolt faces between the intake and exhaust manifolds...



Then I replaced the studs in the upper center area with two bolts. It made it very easy to re-install. I didn't even remove the down tube, it just sat in clean.



Torque-ing the bolt closest to the firewall is an exercise in patience... I used Loctite blue on all the bolts, so I'm hoping that they will stay put for at least another 50k miles.

Thanks to all for your guidance, suggestions and support.

Doug

 

[FJ40Jim]

The toyota gasket pictured is the FelPro graphlex gasket. Did you buy that from the Toy dealer in a toy wrapper?

 

[daflentge]

News to me...

That gasket is Toy part# from Toy Dealer with Toy price... ~$32.

Guess Toyota knows a good gasket when it comes along.

 

[FJ40Jim]

Good to know.
It seems that Toyota has finally flushed the parts distribution system of the chintzy old punched foil gaskets.

 

[JLH911]

Rover - Thx for the tip... Spitfire did a nice job on the manifolds.

I ended up using one Toyota Gasket, and a couple of half washers as shims for the different height of the bolt faces between the intake and exhaust manifolds...

View attachment 481485

Then I replaced the studs in the upper center area with two bolts. It made it very easy to re-install. I didn't even remove the down tube, it just sat in clean.

View attachment 481486

Torque-ing the bolt closest to the firewall is an exercise in patience... I used Loctite blue on all the bolts, so I'm hoping that they will stay put for at least another 50k miles.

Thanks to all for your guidance, suggestions and support.

Doug

Are those shims okay to use? I have a similar situation going right now.

Thanks

 

[klinetime574]

Nice 2F!

Glad you got your issues worked out!

 

[daflentge]

I don't have a leak at this time... but who knows how long they will last.

I had to superglue them in place so that when I installed the manifold, they would stay in place.

I'll do it again, the next gasket replacement.

Good luck on your project.

Doug