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Country Coach Restoration, Repair & Parts Forums => Country Coach Archive => Topic started by: Stan and Joni Vander Ploeg on October 22, 2005, 01:45:47 pm

Title: Engine exhaust manifold ISL 400
Post by: Stan and Joni Vander Ploeg on October 22, 2005, 01:45:47 pm
Yahoo Message Number: 18934 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18934)
Just had CC teck. look in BR engine floor door to look for any problems with rubbing wire and what ever he could see- he found a cracked manifold- he said he has seen a few of them cracked-

Stan vander ploeg
#11556 Intrigue 2003
In Kerrvile, Texas
Title: Re: Engine exhaust manifold ISL 400
Post by: Jim Hughes on October 22, 2005, 06:48:45 pm
Yahoo Message Number: 18941 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18941)
I had found my exhaust manifold cracked and had it replaced two weeks ago.

Jim Hughes

2000 Allure #30511

Quote from: stanley20002152
Title: Re: Engine exhaust manifold ISL 400
Post by: Fred Kovol_01 on October 22, 2005, 07:30:58 pm
Yahoo Message Number: 18942 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18942)
Hi Jim,

I would be most interested how you found the problem and where the crack occurred, how long, width, etc. Is that on an ICS320? How many miles? Exhaust manifold defect or installation issue? Thanks,
Fred Kovol

2000 Allure 30593

Quote from: Jim\[br\
Hughes"]
I had found my exhaust manifold cracked and had it replaced two

weeks
Title: Re: Engine exhaust manifold ISL 400
Post by: Jim Hughes on October 23, 2005, 11:39:28 am
Yahoo Message Number: 18946 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18946)
Hi Fred,

I just uploaded a couple of photos in my folder. I have an ISC330 and it had about 52k miles when I found it on my way back from Alaska. I was in Memphis doing some routine maintenance and troubleshooting a lift pump problem when I found the crack. I typically will pull the under bed cover every few months and inspect the engine over with a flashlight and a mirror. You would be surprised what you find loose or missing. I quit using the exhaust brake for the rest of the trip until I got the manifold replaced. I had Cummins Southeast do the work and made sure thed used all new hardware to reinstall the replacement.

As to wether the crack was due to a bad installation or there was a material defect is hard to say. I looked the all the bolts and the rest of the exhaust system attached and I found nothing missing or any unusual stresses on the manifold. In my entire trip to Alaska and back to Florida I never had any engine temp issues that I was concerned about. I use Sliverleaf VMSpc and had no temp related fault codes. Of course, I use the exhaust brake often. I guess sometime SH*T happens.

The crack by the way, went approximately 180 degrees around the manifold. If it was a stress induced crack, it appeared to be totally relieved. Any further would likely occur over time from vibrations and using the exhaust brake. That was why I decided to drive it on home and get the repairs done here. The exhaust carbon tracks on the head occured between Memphis and Jacksonville. Some, the crack must have just occured when I discovered it. If you notice, the manifold is a two piece manifold.

Take care....

Jim Hughes

2000 Allure #30511

Quote from: fredkovol
Hi Jim,

I would be most interested how you found the problem and where the > crack occurred, how long, width, etc. Is that on an ICS320? How

many
Title: Re: Engine exhaust manifold ISL 400
Post by: Kathy Marsh_01 on October 23, 2005, 12:03:33 pm
Yahoo Message Number: 18947 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18947)

Jim and Fred -

For what it is worth, we also had a cracked manifold last year on our 2000 Allure. Our coaches are very close in number. Jim's coach is #30511, Fred's is #30593 and ours is #30536. Kind of ironic isn't it?

Cummings in Renton, WA did our repair.

Kathy Marsh

2000 Allure #30536
Title: Re: Engine exhaust manifold ISL 400
Post by: Fred Kovol_01 on October 23, 2005, 12:48:05 pm
Yahoo Message Number: 18949 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18949)
Hi,

Scary situation - just added raising the bed access for engine inspection to my punch list. And 5 years was up for me in July of this year.

Fred Kovol

2000Allure30593
Title: Re: Eugene to Reno Route
Post by: Kathy Marsh_01 on October 23, 2005, 01:11:32 pm
Yahoo Message Number: 18950 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18950)

We will be heading south from Eugene on I-5 towards Reno. We are thinking about taking Hwy. 89/94 out of Mt. Shasta going to Susanville. Has anyone taken this route or does anyone have any thoughts - good or bad - about this possible route?

Thanks again -

Kathy Marsh

2000 Allure #30536
Title: Re: Engine exhaust manifold ISL 400
Post by: Ron Schonscheck on October 23, 2005, 02:00:58 pm
Yahoo Message Number: 18951 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18951)
Cracked manifold on our 98 at 40000 miles, also when manifold removed you could see a burned area where the turbo bolts on in the inner wall as well. Of course no warranty. It cost us about 375 for the manifold and about 500 labor at a local truck shop in the Denver area.
Ron 98 Allure 30185

fredkovol wrote:
Title: Re: Eugene to Reno Route
Post by: Bevans2741 on October 23, 2005, 02:57:51 pm
Yahoo Message Number: 18952 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18952)

Hwy 89/44/36/395 to Reno is a very nice drive - 2 lane mountain roads from Mt Shasta to Susanville but should be no problem. Several passes to climb on I-5 thru the Sisiyous.
We usually take Hwy 58 out of Eugene area over Willamette Pass to 97 thru Klamath Falls and then down thru Alturas only because there is only one pass to climb over. We have done both routes and enjoy them both.

Bud Evans

2005 Magna #6451
Title: Re: Engine exhaust manifold ISL 400
Post by: Travman100_4 on October 23, 2005, 04:49:31 pm
Yahoo Message Number: 18956 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18956)
I had cracked manifold on rig early on, at around the two year point it was discovered by Tampa Cummins shop. Replaced under warranty.

Ray

2000 Intrigue 11040

Quote from: Ron Schonscheck\[br\
] >

Cracked manifold on our 98 at 40000 miles, also when manifold

removed

Quote
you could see a burned area where the turbo bolts on in the inner

wall

Quote
as well. Of course no warranty. It cost us about 375 for the

manifold

Quote
and about 500 labor at a local truck shop in the Denver area.
Ron 98 Allure 30185

fredkovol wrote:

> Hi,

> Scary situation - just added raising the bed access for engine > > inspection to my punch list. And 5 years was up for me in July

of this

Quote
year.
> Fred Kovol

> 2000Allure30593

> -
Title: Re: Engine exhaust manifold ISL 400
Post by: James M. Green on October 23, 2005, 08:33:20 pm
Yahoo Message Number: 18960 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18960)
Quote
Quote from: marshshopk@a...
Jim, Fred Kathy and others.

What is the relationship between the Alure coach serial numbers with respect to the same time period of intrigue coaches. They are being built on same chasis with the same batch of engines from Cummins.
My coach I am told was built late 99 and may be in the same batch as those referenced here built as Alure.
James M. Green Intrigue 11021 "Rollingghetto" >

Jim and Fred -

For what it is worth, we also had a cracked manifold last year on our 2000 Allure. Our coaches are very close in number. Jim's coach is #30511, Fred's is #30593 and ours is #30536. Kind of ironic isn't it? >

Cummings in Renton, WA did our repair.

Kathy Marsh

2000 Allure #30536
Title: Re: Engine exhaust manifold ISL 400
Post by: Ron Schonscheck on October 23, 2005, 09:15:03 pm
Yahoo Message Number: 18961 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18961)
Actually in our case the manifold wasn't cracked but rather the gasket was leaking due probably warping of the manifold. Sometimes one can have the manifold ground flat and true, reinstalled and this should solve the problem. However, replacing with a new one is more effective. Someone told me that they had a batch of bad manifolds and a bunch evidently made their way to engines bound for CC's. Of course many highway tractors use the same manifold too.
Ron 98 Allure 30185
Title: Re: Engine exhaust manifold ISL 400
Post by: Gchertz@aol Com on October 23, 2005, 10:25:11 pm
Yahoo Message Number: 18963 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18963)
How many of these coaches actually had the ISL 400 engines

Gordon Hertz

2003 Intrigue First Avenue #11587 ISL 400
Title: Re: Engine exhaust manifold ISL 400
Post by: Larry F on October 24, 2005, 08:03:11 am
Yahoo Message Number: 18968 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18968)
Quote from: gchertz@a\.\.\.
How many of these coaches actually had the ISL 400 engines >

Gordon Hertz

2003 Intrigue First Avenue #11587 ISL 400
Don't know, but I have the ISL 370 and I think it's the same block as the 400. I'm hoping my 370 is running cooler becuse of less horse power (?) and therefore less chance of a cracked manifold. Anyone out there with the 370 that has a crack manifold? Thanks

Larry 2003 Allure #30856
Title: Re: Engine exhaust manifold Cummins engine
Post by: Jim Hughes on October 24, 2005, 09:25:09 am
Yahoo Message Number: 18971 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18971)
Hi Jim

My Allure was also built late 99 and delivered Jan 2000. Not sure what the relationship is. Could be the engines have the same manifold and production lot. The manifolds are a machined casting.
The cracks could be either stress induced or metal fatigue. The crack on my manifold is in a radius. This could be an indication of either type of failure. The stress crack would likely be induced from the mating flange faces not being machined properly or not installed properly. The metal fatigue crack could be a flaw in the casting process. With lab tests it would be hard to say. It just broke. Like Fred, my engine warranty had expired. Fortunately, I have an extended warranty that covered it except fo a $100 deductable and a couple of hardware items I wanted replaced new.

Jim Hughes

2000 Allure #30511

Quote from: rollingghetto
Quote from: marshshopk@a...
Jim, Fred Kathy and others.

What is the relationship between the Alure coach serial numbers

with

Quote
respect to the same time period of intrigue coaches. They are being > built on same chasis with the same batch of engines from Cummins.
My coach I am told was built late 99 and may be in the same batch

as

Quote
those referenced here built as Alure.
James M. Green Intrigue 11021 "Rollingghetto" > >

> Jim and Fred -
>

> For what it is worth, we also had a cracked manifold last year on > our 2000 Allure. Our coaches are very close in number. Jim's

coach

Quote
is #30511, Fred's is #30593 and ours is #30536. Kind of ironic

isn't it?
Title: Re: Engine exhaust manifold ISL 400
Post by: Jim Hughes on October 24, 2005, 09:27:52 am
Yahoo Message Number: 18972 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18972)
My coach, Fred's and I think Jim Green's all have the ISC 330.

Jim Hughes

2000 Allure #30511
Title: Engine exhaust manifold crack
Post by: Dfilter on October 24, 2005, 10:38:09 am
Yahoo Message Number: 18973 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18973)
Jim & Fred,

My coach is a 2000 Intrigue 10938. With a Cummins ISC 350. When I first noticed it at 30,000 miles, my exhaust manifold had about a two inch crack between cylinders three and four. After approx. another 9,000 miles, the crack had expanded 360 degrees. Cummins replaced it under warrany at 39,800 miles on 9/11/01. In discussing the issue with Cummins, they said this wasn't uncommon and they had replaced several, but gave no reason. I now have over 88,000 miles without any further incident.

Denny Filter

2000 Intrigue #10938 Cummins ISC 350
Title: Re: Eugene to Reno Route
Post by: Walt Rothermel_01 on October 24, 2005, 11:44:33 am
Yahoo Message Number: 18974 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18974)
I recently took the hwy 58 route and heartily endorse it as a beautiful drive. Just make sure you have plenty of fuel as there is only a small store on that route with diesel, and they hold it very dear.

Walt Rothermel
03Allure30811
Title: Re: Engine exhaust manifold Cummins engine
Post by: Fred Kovol_01 on October 24, 2005, 12:31:18 pm
Yahoo Message Number: 18975 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18975)
Hi Folks,

It might be helpful to all if we compared engine serial numbers as this might shed some light as to why this is happening and draw some conclusions.
Fred Kovol

2000Allure30593

Engine s/n 45960585 (Found on the inside of the bathroom cabinet door)

Quote
Hi Jim

My Allure was also built late 99 and delivered Jan 2000. Not sure > what the relationship is. Could be the engines have the same > manifold and production lot. The manifolds are a machined casting.
The cracks could be either stress induced or metal fatigue. The > crack on my manifold is in a radius. This could be an indication of > either type of failure. The stress crack would likely be induced > from the mating flange faces not being machined properly or not > installed properly. The metal fatigue crack could be a flaw in the > casting process. With lab tests it would be hard to say. It just > broke. Like Fred, my engine warranty had expired. Fortunately, I > have an extended warranty that covered it except fo a $100 > deductable and a couple of hardware items I wanted replaced new.

Jim Hughes

Quote
2000 Allure #30511
Jim, Fred Kathy and others.

What is the relationship between the Alure coach serial numbers
Quote
with respect to the same time period of intrigue coaches. They are
being built on same chasis with the same batch of engines from Cummins. My coach I am told was built late 99 and may be in the same batch as those referenced here built as Alure.
James M. Green Intrigue 11021 "Rollingghetto" Jim and Fred -

For what it is worth, we also had a cracked manifold last year on
Quote
our 2000 Allure. Our coaches are very close in number. Jim's > coach is #30511, Fred's is #30593 and ours is #30536. Kind of
ironic isn't it? Cummings in Renton, WA did our repair.
Kathy Marsh

2000 Allure #30536
Title: Database created for Cummins Engine Exhaust Manifold Cracks
Post by: Jim Hughes on October 24, 2005, 01:26:49 pm
Yahoo Message Number: 18978 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18978)
Hi Fred,

I just created a data base file for recording exhaust manifold cracks on Cummins engines. If everyone that has had this problem will take a few minutes and fill out the short form in the Database section, I think it would be interesting to see the correlations to model and engine serial number. Just select the Database and add a new record.
If you see any other fields that would be interesting, let me know and I can add it.

Jim Hughes

2000 Allure #30511

Quote from: fredkovol
Hi Folks,

It might be helpful to all if we compared engine serial numbers as > this might shed some light as to why this is happening and draw some > conclusions.
Fred Kovol

2000Allure30593

Engine s/n 45960585 (Found on the inside of the bathroom cabinet

door)
Title: Re: Engine exhaust manifold Cummins engine
Post by: Travman100_4 on October 24, 2005, 07:18:17 pm
Yahoo Message Number: 18984 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18984)
My Intrigue showed the cracked after about three years of ownership.
Built in late 1999, delivered to me in January 2000.
Number 11040, it appears that Cummins had a problem but in my case it was found during the initial Cummins warranty.

Ray

2000 Intrigue 11040

Quote from: fredkovol
Hi Folks,

It might be helpful to all if we compared engine serial numbers as > this might shed some light as to why this is happening and draw

some

Quote
conclusions.
Fred Kovol

2000Allure30593

Engine s/n 45960585 (Found on the inside of the bathroom cabinet

door)

Quote
Hi Jim

> My Allure was also built late 99 and delivered Jan 2000. Not

sure

Quote
what the relationship is. Could be the engines have the same > > manifold and production lot. The manifolds are a machined

casting.

Quote
The cracks could be either stress induced or metal fatigue. The > > crack on my manifold is in a radius. This could be an
indication of

Quote
either type of failure. The stress crack would likely be

induced

Quote
from the mating flange faces not being machined properly or not > > installed properly. The metal fatigue crack could be a flaw in

the

Quote
casting process. With lab tests it would be hard to say. It

just

Quote
broke. Like Fred, my engine warranty had expired. Fortunately,

I

Quote
have an extended warranty that covered it except fo a $100 > > deductable and a couple of hardware items I wanted replaced new.
 Jim Hughes

> 2000 Allure #30511
>

Jim, Fred Kathy and others.

What is the relationship between the Alure coach serial numbers > > with respect to the same time period of intrigue coaches. They

are

Quote
being built on same chasis with the same batch of engines from > Cummins. My coach I am told was built late 99 and may be in the

same
Title: Re: Engine exhaust manifold ISL 400
Post by: Kathy Marsh_01 on October 24, 2005, 10:47:10 pm
Yahoo Message Number: 18986 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/18986)

Jim -

Our 2000 Allure #30536 also has the ISC330 engine. The serial number is 45935438.

Kathy Marsh
Title: Re: Engine exhaust manifold ISL 400
Post by: Don & Janet Scott on October 28, 2005, 12:15:26 am
Yahoo Message Number: 19050 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/19050)
I have a cracked exhaust manifold on my ISC too. This one is real easy to see-right between the #3 and 4 cylinders. There is some extra noise and the pac break is noticably less effective. I just had the coach in for service at Garantee in Junction City and specifically asked that they check for any cracks as I knew it was a common problem on the ISC. The coach has a little over 60,000 miles. I would urge all to take a good look before their warranty is up.

Don & Janet Scott
02 Allure #30799

VW R32, MUTT & BMW F650
Title: Re: Engine exhaust manifold ISL 400
Post by: Fred Kovol_01 on October 28, 2005, 10:54:18 am
Yahoo Message Number: 19061 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/19061)
Hi Don and Janet,

Please consider adding your failure to the database.
Thanks,
Fred Kovol

Quote from: Don & Janet Scott
>

I have a cracked exhaust manifold on my ISC too. This one is real
easy to see-right between the #3 and 4 cylinders. There is some extra noise and the pac break is noticably less effective. I just had the coach in for service at Garantee in Junction City and specifically asked that they check for any cracks as I knew it was a common problem on the ISC. The coach has a little over 60,000 miles. I would urge all to take a good look before their warranty is up.
Title: Re: Engine exhaust manifold ISL 400
Post by: Dennis McCarthey on October 11, 2006, 12:03:33 am
Yahoo Message Number: 25787 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25787)
Kathy and all,

I know this is old news to you all, but I found a crack in my exhaust manifold this past weekend while lubricating a sticky Pac brake mechanism. Just scheduled an appointment for repair (first of any repair for me) at Cummins NW in Renton Wa.
Kathy can you provide cost and repair time details?? Thanks in advance

Dennis McCarthey
Port Ludlow, Wa
2000 Allure #30533

Quote from: rollingghetto
Quote from: marshshopk@a...
Jim, Fred Kathy and others.

What is the relationship between the Alure coach serial numbers with > respect to the same time period of intrigue coaches. They are being > built on same chasis with the same batch of engines from Cummins.
My coach I am told was built late 99 and may be in the same batch as > those referenced here built as Alure.
James M. Green Intrigue 11021 "Rollingghetto" > >

> Jim and Fred -
>

> For what it is worth, we also had a cracked manifold last year on > our 2000 Allure. Our coaches are very close in number. Jim's coach > is #30511, Fred's is #30593 and ours is #30536. Kind of ironic

isn't it?
Title: Re: Engine exhaust manifold ISL 400
Post by: Jim Hughes on October 12, 2006, 08:56:33 am
Yahoo Message Number: 25831 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25831)
Dennis

Please take the time to add your coach info to the Database file we started on this subject several months ago. It is interesting to see the trend on certain models and years.

Jim Hughes

2000 Allure #30511

Quote from: Dennis McCarthey
Kathy and all,

I know this is old news to you all, but I found a crack in my

exhaust

Quote
manifold this past weekend while lubricating a sticky Pac brake > mechanism. Just scheduled an appointment for repair (first of any > repair for me) at Cummins NW in Renton Wa.
Kathy can you provide cost and repair time details?? Thanks in

advance

Quote
>

Dennis McCarthey
Port Ludlow, Wa
2000 Allure #30533

[quote author=rollingghetto"

>

> -
Title: Re: Engine exhaust manifold ISL 400
Post by: Dennis McCarthey on October 12, 2006, 09:34:01 am
Yahoo Message Number: 25832 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25832)
Jim,

Found the "cracked manifold" file and added my info to the list.

Dennis

Quote from: Jim Hughes
Title: Re: Engine exhaust manifold ISL 400
Post by: Kathy Marsh_01 on October 12, 2006, 03:48:06 pm
Yahoo Message Number: 25845 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25845)
Dennis -

As I recall, ours was corrected while the coach was still under warranty. It was done at Cummins in Renton, WA and I believe we were there for two days. We were able to stay in the coach at night.

Kathy Marsh

2000 CC Allure #30536

Currently in Albuquerque for the Balloon Fiesta
Title: Re: Engine exhaust manifold ISL 400
Post by: TOM A COOPER on October 12, 2006, 04:28:18 pm
Yahoo Message Number: 25847 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25847)
How do I get to the list to enter my coach info?

Tom Cooper

2006 Allure # 31364
Title: Re: Engine exhaust manifold ISL 400
Post by: Jim Hughes on October 13, 2006, 08:30:30 pm
Yahoo Message Number: 25891 (http://groups.yahoo.com/neo/groups/Country-Coach-Owners/conversations/messages/25891)
Go to the groups website and look to the left you will find Files, Photos, Links and Database. Select Database and then go to the manifold file.

Jim Hughes

2000 Allure #30511

Quote from: TOM A COOPER
How do I get to the list to enter my coach info?

Tom Cooper

2006 Allure # 31364
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