Baller matt_b Posted January 11, 2016 Baller Share Posted January 11, 2016 On both exhaust manifolds there is water leaking out of what looks like a pinhole. There is a spot on both manifolds that looks like a weld? where the leaks are forming. Can this be cleaned up and patched with an epoxy, or maybe welded ? Thanks for any great suggestions. Link to comment Share on other sites More sharing options...
Baller gregy Posted January 11, 2016 Baller Share Posted January 11, 2016 Got any pics. Link to comment Share on other sites More sharing options...
Baller oldjeep Posted January 11, 2016 Baller Share Posted January 11, 2016 Sounds like the casting plugs are rotting out. Start reading here: Lots of folks who have experienced the problem with the ETX manifolds and done a few different things from drilling and epoxy, removing them and having new plugs welded in or swapping on the cast iron manifolds. Link to comment Share on other sites More sharing options...
Baller LZywicki1 Posted January 11, 2016 Baller Share Posted January 11, 2016 Had both of my exhaust manifolds welded, not a big problem. Just find someone in your area that does aluminum welding. Have the casting plugs ground down and welded over. I bought some new plugs from Indamar, about $1.50 each, welder I used didn't need them. Larry -----<| Link to comment Share on other sites More sharing options...
Baller MichaelGoodman Posted January 11, 2016 Baller Share Posted January 11, 2016 J B weld will work fine. Link to comment Share on other sites More sharing options...
Baller wolfgang Posted January 11, 2016 Baller Share Posted January 11, 2016 I agree with all the above. Happened to my 2004 LXI too. Easy to remove headers yourself...a capable aluminum weld shop will have no problem making the repair. It seems to occur at the casting gate where the plug has a different aluminum metallurgy , leaving the spot susceptible to galvanic corrosion. I now carry JB Weld in case it happens again. No gaskets are necessary when reattaching the headers, just a quality liquid gasket maker Link to comment Share on other sites More sharing options...
Baller matt_b Posted January 13, 2016 Author Baller Share Posted January 13, 2016 Thanks for the comments, here is a photo, Link to comment Share on other sites More sharing options...
Baller wolfgang Posted January 13, 2016 Baller Share Posted January 13, 2016 Yup....I had two that leaked ,on one side only, that looked exactly the same. I'm expecting the other side to leak some time soon. The original leak occurred as soon as I in-winterized the boat. Link to comment Share on other sites More sharing options...
Baller wolfgang Posted January 13, 2016 Baller Share Posted January 13, 2016 ....Occurred as soon as I "un-winterized" the boat early in spring.... Link to comment Share on other sites More sharing options...
Baller lff Posted January 13, 2016 Baller Share Posted January 13, 2016 I have an 03 and I replaced them a year or so ago. I figured after 12 years it was time. Link to comment Share on other sites More sharing options...
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