What are your intentions for the rest of the exhaust system?

 

I have the long bed parts truck tail pipe, muffler & intermediate pipe installed in the truck.

The new Y pipe is only 6" short of the intermediate pipe (no cat) so tomorrow I am hitting the parts store to see if I can buy a short pipe that will join the system as one.

I cant remember if there was any room between Y pipe & muffler for the cat as I was not going to use a cat to look that close.

Looking over online parts stores it looks like you could run the EFI system all the way back if you wanted to.

I will get pictures of that part tomorrow.
Dave ----

 

It was a little cold (45*) in the garage but I finished connecting the Y pipe to the rest of the system.
Y pipe from the left and the older stock pipe before the muffler on the right.

The gap that had to be bridged

Not pretty but it works. I would have had to order the pipe and did not want to wait for it.

I forgot to see if the cat would fit between the Y pipe and muffler - it was too cold!
Dave ----

 

So, figured this would be a better place to ask than the other thread, since you've covered many of the issues here already. Anybody know if the issues with the height of the intake and exhaust manifold fastener locations being different are resolved by the use of an Offy or Clifford intake?

If so, anybody have a reasonably priced intake they want to part with?

 

If you go to the 240/250/300 I6 area I think there is a post about an issue a member had of ears breaking off on the intake but I don't remember why at this time.


For me I found the best way was to take a belt sander to the higher part, the exh manifold, to level them out.
I have not started the motor yet and will not for some time but I don't see why I would have any issues.
Dave ----

 

Here are a few links I looked at before I did my swap.
https://www.ford-trucks.com/forums/1...-breaking.html

https://www.ford-trucks.com/forums/1...-question.html

https://www.ford-trucks.com/forums/1...olds-swap.html

https://www.ford-trucks.com/forums/1...manifolds.html
Dave ----

 

Right on. Thanks Dave. I might have a few other questions later. Much appreciated.

 

Hey Dave, or anybody, do you happen to know if the carbureted intake manifolds off the vans are different than those on the trucks? The reason I ask is that the ones on the trucks clearly have different length runners on one end than on the other, and the one I'm looking at on ebay, listed for the E series vans, does not appear to be that way.

It's not an aftermarket unit, it's a factory intake, but it does not seem to have shorter runners on one end than on the other. Industrial unit maybe? Looking at MY intake, it clearly has asymmetrical runners and the van unit looks definitely different than mine when standing on the mating surface.

 

I don't see or know what it is you are talking about as they both look the same other than the angle of the pictures between them.
Can you post a picture of you intake and show what you are worried about.


Below are pictures of mine from when I was doing the EFI exh swap.



What I do if I want to see if parts are the same between models is look the parts up on say Auto zone or Advance Auto for both parts and see if they both have the same part numbers.
If you are doing the EFI exh manifold swap and using the stock intake manifold (like I am) I think you might be over thinking this.
Dave ----

 

@Fuzzface2
Hi Dave - can you explain this a bit? I am pretty new to the Ford scene and am about to tackle this swap. I am not sure I understand where this hole is.
Also, when the EGR pipe was removed, what happens at the end that is attached to the EGR Plenum? Do I just leave it open?
Also, I am not sure what I am looking at in this picture:

Is that the expansion plug showing the EGR port you had to fill in the quoted sentence above?
I have a new catalytic converter that was in the pile of parts I got with the truck. Should I bother to put it on and if so, should I connect it directly to the end of the Y pipe just before the muffler or do I need some room between it and the Y pipe?
I think I understand what you were talking about when you mentioned milling the manifold or the washers. I ran into the same thing when installing a header on an old Land Cruiser (also a straight 6). I ground washers down and used a Remflex gasket and that was pretty forgiving.

Incidentally, I got my intake manifold heater here: Intake Manifold Heater Kit - Ford 240/300 (Raso Enterprises).

I have the Y pipe, manifolds, studs, washers, manifold heater, grey Permatex and a Remflex gasket.
I need the expansion plug, some 7/16 bolts and 3/8 -24 nuts
Anything else I am forgetting before I get into it?

Cheers
Hugh

 

Hugh, I will post answers when on my pc.
At work and on my phone it is hard.
Dave - - - -

 

Let see if I can answer your questions now that I am on my PC.
That hole that I put the expansion plug in is in the intake manifold under the EGR plate. If you pull the carb off then the EGR plate you will see the hole.

The pipe at the EGR valve end I think I left open. No exh. can come from the intake side as I installed that expansion plug and the EGR valve can not open because I do not have any hose hooked to it.
The other end where the pipe was hooked to I used I think it was a 3/4" threaded pipe plug after I removed the adaptor.

That picture is the intake manifold with the carb & EGR plate / valve removed and the expansion plug installed just like you thought.

On the catalytic converter if you install it it will need air pumped to it from the air pump and all the switches & valves hooked up and working, that is how stock was.
Do you need any of that mess to pass emissions? If not do like I did and not install the catalytic converter and I have a new one as it comes with the Y pipe.
I used a piece of pipe between the end of the Y pipe and the middle exh pipe before the muffler. I hoped the exh. note would of been a little louder with out the catalytic converter but it is not.

I also had a 73 LC FJ40, A buddy gave me his header - Clifford, Holley 2300 carb & adapter to the stock manifold, when he dropped a 350 Chevy in his 72 FJ40.
It was a long time ago but don't remember any issues with the manifolds & washers like this swap on fords. I do miss my LC but after racing it off road for years and rolled a few times I would not been good to go back on the road.

My heater is a little different then that but yours should work. The place I got it from on Ebay does not sell there any more and I don't have a good link to find them.
The only thing I can think of is a gasket between the heater plate and the intake manifold. I made mine from a sheet I got at auto parts store. I think I used a stock gasket as a pattern.Did not think the stock one would not leak and why I made one.

Also before putting the gasket on set the plate in place on the intake to see if it sits flat. I don't think you will have any issues as your plate was drilled & taped for the fittings. My fittings were welded from the back side and the welds hit a divider inside the manifold so I had to grind down the divider a little for it to sit flat.
Just mock it all up on the bench first and you should be good for install.

If you have any questions just ask.
Dave ----

 

Thanks much. You cleared up my questions. I thought of welding the hole you put the freeze plug in but would be concerned about damaging my intake. I am just waiting on my studs and I will get to it. I won't bother with the cat. Most of the emissions stuff is off the truck already and we do not have to smog here in rural VA. Clearly it would not work properly if installed now. I haven't messed with anything "new" enough to have a cat (sounds funny to say). My Y pipe also came with a new one. Maybe I can make a deal with the muffler shop and trade it to them if I need them to do anything with the muffler or pipes

One last question: There is no gasket at all between the y pipe flanges and the exhaust manifolds, correct? It is just a friction fit made by the convex part on the Y pipe into the concave on the manifold?

 

To weld cast iron it needs to be heated in an oven first and a cast iron arc rod is needed.

Now maybe you don't need to plug that port? I thought something like coolant would be there and why I did?
If coolant was the case and the gasket between manifold & EGR plate or EGR plate & valve it could be pulled into the intake and burned.
It would show up like a blown head gasket, white sweet smelling smoke out the exh. pipe.
You would pull the head and not find a bad gasket so you think cracked head or? I just did not want to go down that rabbit hole!

On the cat it sounds like you should not install it.
Yes the Y pipe and manifolds fit together with out a gasket. The cones fit into each other and seal.

The other thing I used anti-seize on all nuts & bolts so if I need to pull it apart it should be easy.
Dave ----

 

Good copy. I am thinking with my heater plate that hole will get sealed but, like you, in abundance of caution, I think I will stick a freeze plug in there. I am really interested in seeing what type of seat of the pants gains I may get in the old girl. Thanks for all your help. I will post up pictures here if I run into anything odd. :cheers: