Have a auto shop with a machine shop resurface it.........$15.00 last time I had it done.
Your old OEM is better than a new Dorman.

$230 for pacesetter 50 state legal shorties. i dont know what your budget is but i have these and i love em. could do em now while your already having exhaust issues

Back together and running good now. I can't believe how quiet it is with the manifold leak fixed. It may be me, but I think it runs better too. After a test drive, I pulled codes and everything is clear. After having the battery out of it for 3 days, the computer is relearning the parameters, and hopefully, the codes will not return.

I agree that an OEM manifold is better than an aftermarket replacement, but I simply didn't have any other choice. I need the truck back in service to go to the airport Monday morning (I take the truck instead of my "good" car to sit in the parking garage). Resurfacing the original wasn't an option this time. In addition to being warped in the axis that mates to the cylinder head (fixable), it was also warped along the length (think banana), causing the holes not to line up; not even close. There's no fixing that. The Dorman DID fit like a dream, and looks like a decent piece. Time will tell if it holds up, but others here have had good luck with them in this application.

Same thing for the headers; no time. Also, I just don't like fooling with headers, and have no plans to modify the truck whatsoever, single exhaust and all. Plus, they always seem louder (through the firewall), which is exactly what I was trying to avoid. If I have more manifold issues in the future, these may be the way to go to avoid further warping hassles.

Thanks for all the great input!

JD

Glad to hear you got everything back together.

Get summit brand headers - they are Pacesetters (even has a pacesetter sticker in the box) Only run about $170. I'm not usually a Pacesetter fan, but they have pretty thick metal on them as well as thick flanges.

I'm running into a bit of a problem installing mine, though. I took off the driver's side no problem, but I've only taken out one bolt on the passenger side and it broke right at the head. Looks like I may have to take off that head in order to extract the remainder of the bolt, as there is no room to get any tools down there.

Thanks for this thread, I'm prepping a 5.8 to go into my F250 and the right side exhaust mani has a crack between cylinder 2 and 3 plus my EGR tube flex joint was non-existent. I basically have no budget to work with so I wasn't sure what to do about the broken manifold. I've seen the Dorman replacements on fleabay but I was too sure about them, your review helped me to decide to give it a try.

PCI Inc. sells the EGR tube. Rock Auto carries them as well.

I have had the Dormans on my F350 for almost two years now with no issues.

UPDATE
 

Just a quick update on my Dorman exhaust manifold. It's been a few years since I installed it, and it's still working great. No leaks or other issues. So, from my personal experience, I'd say that it's a decent piece that has served well so far. Just wanted to update this in case someone is in the same position as I was, and is wondering if the Dorman is a viable option. It is.

Cheers,

JD

When you took the manifold off originally, how did you manage to remove the bolts without breaking any?

Did you use any heat, special tools?

+1 on the above. I am trying to decide on doing mine in the garage or paying a shop. I am going to do pacesetter ceramic coated long tubes though.

Z

I soaked the manifold bolts with PB Blaster for a few days. I also ran the truck for a few minutes each day. I did the same thing just before I started the R&R. When I felt a bolt was not coming out easily I applied a little heat with a propane torch and more PB.

None of my bolts broke on me . Heat, PB and time are your friend. My truck was not a DD so I had the luxury of time too.

Did you reuse the old bolts?
Mine are pretty corroded, so getting new would probably be the best.

Chuck them and get new ones...

I have to pull my passenger side manifolds, as one of the bolt heads is snapped off, and that may be causing the leak.

I'm really not looking forward to it. Trying to find a small oxy setup before I even think of starting it, and also a time when I can have the truck down for a while...

I've found in the past that removing the bolts when the engine is warm, sometimes helps. PB blaster is definitely one of the most amazing things I've ever used...

I took mine for a long drive today after a good ole tune up.
Came home and was finally able to crack lose the EGR tube, it was seized pretty good.
I will do the same for the O2 sensor and the exhaust manifold bolts.

NEVER re-use old ex-manifold bolts, you are lucky when they come out in one piece, let alone going back in to torque.
Get new non-plated grade-8 bolts.