 | Home > Tdi > Downpipe resting on crossmember |
 
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1624   
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Aftermarket chassis? Have you got the exhaust mount on the side of the gearbox fitted?
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24th May 2023 11:45am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410 
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It is not uncommon for the exhaust to engine block bracket to shear in two and allowing the down pipe to drop down the manifold exit. I had this a few times on my 200tdi.
There should be a mount to the engine block and the clamp holding the exhaust to the manifold. |
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24th May 2023 11:50am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 909
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It is an aftermarket chassis. The pipe to block bracket is not connected either. It is tight up against the top of the manifold though, hasn't slipped down.
The gearbox mounts look a little soft and perished. I am going to remove the rear section of the exhaust and loosen the manifold bracket and see if there is any play / adjustment to be had. And see if putting a jack under the gearbox and lifting it slightly helps at all. Thanks |
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24th May 2023 2:33pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Good call I just noticed the ARB mount ion the photo  |
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24th May 2023 2:54pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Check your engine mounts have not collapsed either. If all looks good trimming the exhaust down by 10-20mm would probably sort the problem out. |
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24th May 2023 2:55pm |
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3414  
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I see 2 problems:
1. The genuine gearbox cross member, the pipe is welded lower, so that the ends of the pipe are partially open. 2. The exhaust section between the downpipe and the central box should bend upwards and then downwards again, that is it higher over the crossmember and closer to the bellhousing. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing 2012 90 CSW, 2.2TDCI, Santorini Black |
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24th May 2023 4:24pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6092 
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Mine used to do this also... the little tab on the downpipe that corresponded with an M8 thread cast into the block, has a short bolt that located it (which was always a royal PITA to get lined up), the tab would snap off then the downpipe would slide down the exhaust "tube" off of the turbo. |
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24th May 2023 5:16pm |
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| I Like Old Skool Member Since: 23 Feb 2015 Location: Manchester Posts: 808 
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I had a 200tdi and the engine mount bracket was a PITA. I seem to remember having to re-weld the mounting tabs after they fractured????
As has already been said, make sure the exhaust is fully pushed home on the turbo and clamped tight with the engine mount bolts correctly in place. Unless you have a god awful alignment issue with aftermarket exhaust pipes and aftermarket chassis then it is just a case of optimising the alignment to give clearance. It does fit, just get it right....... |
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2nd Jun 2023 10:53pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 909
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Thanks all.
I suspect it is a combination of issues. The shielded chassis won't be the best, the downpipe was a cheap ebay job and the engine and box mounts are poor. The pipe is hard up against the turbo so no space to be gained there. I will look at the mounts more closely and if nothing to be gained there see if I can trim some off the top of the downpipe. |
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3rd Jun 2023 9:27am |
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| Procta Member Since: 03 Dec 2016 Location: Sunderland Posts: 5163
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I often wonder if its a 200TDI thing, because my dads vibrates like hell, i think it could be a design flaw in the down pipe with it been solid fitted to the engine block. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back
Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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8th Jul 2023 8:02pm |
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| Dukeofastley Member Since: 27 Dec 2008 Location: Shropshire Posts: 6
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Hi - I had exactly this issue.
I took the crossmember off and cut a scoop out of it . Hopefully photo attached . Andrew  Click image to enlarge |
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24th Jul 2023 12:18pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 909
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I did contemplate that as an option. My welding is not good enough so I'd have to get that done though. Bit of a shame on the galv chassis as well.
I am going to try the simple things first, once I get my mojo back. I have replacement gearbox mounts and I'll also try cutting a bit off the top where it meets the manifold. If that does not help, on to more drastic measures. |
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24th Jul 2023 6:44pm |
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| Dukeofastley Member Since: 27 Dec 2008 Location: Shropshire Posts: 6
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Yes. I know what you mean about the galv chassis. I had the same thoughts but I had no option. I used galv spray after it was all welded up and it looks a treat. You would never know.
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24th Jul 2023 7:21pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 214 
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I had a similar issue (pre Td5-swap), the cheap downpipe I'd bought was longer at the top (where it mounts to the turbo) than the original, meaning it then hung too low for the block bracket and also clashed with the crossmember.
I ended up trimming it down which solved the issue. 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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27th Jul 2023 2:52pm |
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