Busted downpipe flange at the turbo!?

[WarWagon]

Anyone ever had this happen?

Using the aluminum Heartthrob kit (that SS diesel supply sells although I did not obtain it from them).

Had a rattle in the exhaust. Figured it was a bad clamp. When I took the clamp off it looks like the flange broke off on one side of the down pipe where it attaches to the turbo.

Curious as to what would cause this.

 

[NVW]

There must be some vibration to cause it to break there, and maybe there was a manufacturing crack when they formed the lip

 

[bk95td]

Loose motor mounts could cause that. It is usually the passenger side mount that is the loosest. Engine moves more than pipes can. Here's a pic of the passenger side motor mount that came out of my 93. The truck had a 5th wheel hitch in it when I bought it

 

[buddy]

I have the darndest time even getting the turbo elbow and downpipe to line up, and I dont think I ever even get it right, because the downpipes dont seem as large diameter as the elbow, so although the side I can see is in, the other side is not and I end up tightening the clamp without the downpipe inside it all the way around.

So one of the three parts around the clamp is caught on the downpipe flange and the more you tighten the more its bending it backwards against the force of the outer band.

 

[Matt Bachand]

I have the darndest time even getting the turbo elbow and downpipe to line up, and I dont think I ever even get it right, because the downpipes dont seem as large diameter as the elbow, so although the side I can see is in, the other side is not and I end up tightening the clamp without the downpipe inside it all the way around.

So one of the three parts around the clamp is caught on the downpipe flange and the more you tighten the more its bending it backwards against the force of the outer band.

I have the same problem buddy. I 'settled' for as little leak as possible there. If I block my exhaust off I can hear it escape there, but can't hear it normal driving. I've never tried with 2 people though.

 

[DieselCash]

It took two people to reinstall my down pipe. One to hold it up and one to apply the clamp. It is a lot easier to install the down pipe with the inner fender removed. Taking out the inner fender is not that difficult and not that easy all in one.

 

[WarWagon]

Do I need a new downpipe or can this flange be fixed?

Engine mounts are new.

 

[NVW]

If you or someone you know has a MIG or TIG welder it could be welded and then ground back to the original contour. If it could be welded on the inside the back weld would give it extra strength. Maybe all it would need is the weld on the inside.