Hole Rusted Through Head
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5th Wheeling
Joined: Dec 2024
Posts: 28
Likes: 7
Hole Rusted Through Head
I'm in a little bit of a predicament. My 01 7.3 developed a bad exhaust leak on the passenger side. I took it to a nearby shop, and they said that a hole rusted through the passenger side cylinder head. Apparently, it was most likely caused by the AC condensation dripping onto it.
They want $4500 to put in a remanufactured head and a new exhaust manifold. I'm not entirely positive it's worth it to have it done; the truck has 290k miles and obviously has some rust on it and several other issues (engine shakes bad at 1500rpm, leaking pinion seal, engine leaks oil, hydroboost leak, the list goes on). I thought about fixing it myself but I'm not entirely confident in doing it. Anyone know if this is something that could be DIY'd? Would I be better off swapping in a different motor?
They want $4500 to put in a remanufactured head and a new exhaust manifold. I'm not entirely positive it's worth it to have it done; the truck has 290k miles and obviously has some rust on it and several other issues (engine shakes bad at 1500rpm, leaking pinion seal, engine leaks oil, hydroboost leak, the list goes on). I thought about fixing it myself but I'm not entirely confident in doing it. Anyone know if this is something that could be DIY'd? Would I be better off swapping in a different motor?
Lead Driver
Joined: Jun 2004
Posts: 6,340
Likes: 588
From: Amarillo, TEXAS!
It sure does look like a chunk of cast iron is missing. I can't see how it could possibly be from A/C condensate, but it is what it is, I guess. If the condition of the rest of the engine or truck is like that, it may not be worth putting any money into it.
Laughing Gas
Joined: Jul 2011
Posts: 836
Likes: 213
I can't see how the condensate could cause a rust hole. Could you pressurize the coolant system and see if it actually leaks?
I don't normally condone this but would a high grade of JB weld possibly fix the coolant leak?
Depending on the size of the hole diameter leak, could it be tapped for a 1/16" NPT pipe plug or a fine threaded bolt?
Rob.
I don't normally condone this but would a high grade of JB weld possibly fix the coolant leak?
Depending on the size of the hole diameter leak, could it be tapped for a 1/16" NPT pipe plug or a fine threaded bolt?
Rob.
Laughing Gas
Joined: Aug 2023
Posts: 972
Likes: 359
From: Glendale, AZ
Need to take some time and have a go at that head to clean it up. Cant really see what's going on w/ the head, and how bad it really is. Could just be threaded and plugged or possibly welded in, or it may be trash, all depends on how bad it's gone. Kinda surprised if it's that rusted that the manifold bolts look like they're in relatively decent shape.
Also not sure how the condenser could leak on them.
Also not sure how the condenser could leak on them.
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It's a Van Gogh
Joined: Feb 2010
Posts: 7,812
Likes: 1,335
From: Elk Grove, CA
Mind blown on the rust level. Looks like head cannot seal to the manifold due to chunk blown off. 
Time to take stock of the entire rig with rust the main lens.
Imo $4500 for new head and manifold is entirely reasonable.
Time to take stock of the entire rig with rust the main lens.
Imo $4500 for new head and manifold is entirely reasonable.
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Mountain Pass
Joined: Nov 2020
Posts: 220
Likes: 34
From: Orcas Island
That is a lot of rust! I work on boat engines in salt water environment and I don't think I have ever seen that much scale rust on a cylinder head. Is it that round depression above the exhaust bolt, center of picture? Do you have good access to it? can you tap around it lightly with a slag hammer and try to determine by the sound if there is enough metal around it to hold threads? I'm thinking perhaps a 1" pipe plug with red loctite and don't over tighten it? This will not be a permanent repair but you might get up to a year out of it while you shop around for another engine or another truck.
Fleet Owner
Joined: Jun 2004
Posts: 25,090
Likes: 1,112
From: Rio Rico, AZ.
I would say that the level of rust deterioration is due to a couple of decades worth of road salt and not AC dripping. The AC outlet is positioned well below the level of the exhaust manifold and whatever drips gets blown back. Some hard decisions await your consideration on this one.
Go Bills !
Joined: Jan 2008
Posts: 2,778
Likes: 65
From: Buffalo, NY
This Thread is confusing, If you click that picture, It shows you a few more pictures and you can see responses that don't show up in the main thread, Says 9 reply's but there is way more. Some settings or something?
I hate to say it, Because I will tackle any job, But without seeing the rest of the truck I would consider scrapping it and picking up another older truck that hasn't see any salt. I live in high salt area, I won't buy anything used from up here, I will grab one from down south. Maybe its time for something a little newer and cleaner. That would be money more wisely spent in my opinion.
I hate to say it, Because I will tackle any job, But without seeing the rest of the truck I would consider scrapping it and picking up another older truck that hasn't see any salt. I live in high salt area, I won't buy anything used from up here, I will grab one from down south. Maybe its time for something a little newer and cleaner. That would be money more wisely spent in my opinion.
It's a Van Gogh
Joined: Feb 2010
Posts: 7,812
Likes: 1,335
From: Elk Grove, CA
This Thread is confusing, If you click that picture, It shows you a few more pictures and you can see responses that don't show up in the main thread, Says 9 reply's but there is way more. Some settings or something?
I hate to say it, Because I will tackle any job, But without seeing the rest of the truck I would consider scrapping it and picking up another older truck that hasn't see any salt. I live in high salt area, I won't buy anything used from up here, I will grab one from down south. Maybe its time for something a little newer and cleaner. That would be money more wisely spent in my opinion.
I hate to say it, Because I will tackle any job, But without seeing the rest of the truck I would consider scrapping it and picking up another older truck that hasn't see any salt. I live in high salt area, I won't buy anything used from up here, I will grab one from down south. Maybe its time for something a little newer and cleaner. That would be money more wisely spent in my opinion.
Those 2 other pics are from the "Related Thread" below the current thread. Scroll down you'll see them.
Lead Driver
Joined: Apr 2016
Posts: 7,205
Likes: 1,340
From: Bahstun
Leaf blower on the tail pipe, soapy water sloshed on engine.... will show bubbles aka your leaks
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