Cracked 2.7L exhaust manifold

So yesterday I was just nosing around the engine bay, like I do occasionally around all parts of this truck, and decided to remove the heat shield on the exhaust manifold to take a look underneath. Once I pulled the heat shield, I found this:





While I have noticed no performance loss or noise whatsoever, I figure this is something that should be addressed before it gets worse. So I got a couple of questions for the board before I jump into replacing the manifold:


I.) A quick look around my favorite parts sites shows that the only readily available OEM type replacement for this manifold is the Dorman 674-464:


I can get this delivered for about $90 from Rock Auto. Although I've had good luck with Dorman parts on this truck in the past (leaf springs), the cuts on the actual manifold look real rough and sloppy from the photos and are causing me some hesitation. Does anyone have any experience with these?

II.) Are there any alternatives to the above manifold? My priority for the truck is reliable daily driver performance - not interested in upgrading exhaust tone or power or anything like that.

III.) I read somewhere online that removing the studs from the head may cause the threads in the head to strip. On my truck, I tested one of the easy to access nuts and studs and the nut had welded itself to the stud so both the nut and the stud came off as one piece. Is there any precautions or techniques I should use to try to avoid stripping the threads in the head? I have Liquid Wrench on hand and will be using it liberally.

Any other inputs, tips, and tricks would be much appreciated as well.

Thanks!

 

Sub
I think I am in the same boat except I have an exhaust leak in that area. I have not taken the heat shield off to look yet.

 

this is very common on the 2.7l. alot of people will just swap them to the newer tubular manifold from I believe 01ish to 04 trucks. I think they run a little over $200 bucks from what I've read and may have a little more performance with less chance of cracking than the cast ones. Or there's always the performance header options which range from under $200 bucks for the pacesetter up to $500ish for the better quality stuff. My trucks just a beater hunting rig so I through the pacesetter on it, most people don't like them cuz they're not built as sturdy as the higher end ones but aside from the crappy gaskets it came with I've had no problems. As to the gettin the nuts off if you don't have to drive it a couple days before you do the job start soakin them with pb blaster or whatever penetrating oil ya got then just tak'm out nice and easy. It shouldn't hurt anything if the stud comes out with the nut just don't over tighten and strip out the head when you reinstall them. My truck was pushin 300k when I did it and the nuts came right off

 

Good input Vern, thanks,

 

I could definitely feel the loss of power. Change that out before it gets worse. And like yours, mine was only "slightly cracked"...

http://youtu.be/SDxx2vC5Uq8

I got the kit from DeathCougar on yotatech, it was around $300, and pretty easy to install. I didn't replace the heat shield.

 

Got a good manifold off 96 2.7. Center bolt on heat sheild sheared. Otherwise perfect.

 

How much? What part of VA?

 

This is what I replaced the cracked manifold in my old '98 5 lug with. A little more than what you probably want to spend but well worth the investment.

http://www.yotatech.com/f37/tacoma-4runner-2-4l-2-7l-mini-header-kit-now-available-179930/

 

Andy,

See my PM please.