H9FA Exhaust Manifold alternative part? Help!

[trannynick]

Afternoon. The turbo on my 2004 2.4 tdci 135 6 speed was beginning to seperate from the manifold due to corrosion around the bolts and was blowing badly. I removed the manifold and all 6 bolts in the housing have all snapped, (they werent budging at all), The manifold is now scrap and has multiple cracks inside anyway. This manifold is like hens teeth and cant be had anywhere at an affordable price - What are my alternatives? Can you guru's help me out here, I cant access any ford diagrams, they seem to have all been took down. Can i fit the manifold and turbo with the large band clamp from a later 2.4 tdci? I found a post somewhere where they had similair problem and stated they did that swap.. Mine is a vacuum controlled variable vane setup with no wastegate. One place does them remanufactured for £600 which is too much money. If i can stick a used setup from a later 2.4tdci for a couple of hundred im hoping, Im not knowledgable on interchangeability, hopefully someone will know. Thanks in advance.

[metalworker0]

They only list it on the parts diagrams site, manifolds complete with turbo .. 6 choices.. press on number one in the diagram scrolls you down to the choices highlighted

You can put your vin number into the site and get the exact one

But don't think with the part number you are going to find any new

http://www.catcar.info/ford/?lang=en&l= ... I3Mg%3D%3D

if you put 2.4 transit turbo manifold into ebay.. several come up .. lowest "£75 without the turbo .. this is used.. no idea if it fits yours.

first one that comes up .. looking like yours is £149 ..includes turbo

ebay sellers never include enough detail or condition description .. BEWARE

all the best.mark

[trannynick]

Thats really helpful, i put my vin in and its part number 1590100 - Seems it was a short lived part - If i cant find one cheap enough i will probably have a machine shop try and remove the broken bolts, im not too bothered about the cracks in the housing now ive seen the price of a remanufactired used one. My cartridge is good, the shaft has no play. I will clamp it back down with some washers, that was my plan initially, until everything snapped. (theres one on ali express but its all in russian, i will try and navigate that) As always, many thanks for the help.

[T350camper]

A machine shop should be able to remove those snapped bolts and cut new threads. Maybe (if they're good enough) even weld the cracks. Cast iron is not straightforward to weld. Not everywhere can do it. Even without this, I'd try fixing this one first. Let us know how you get on. Good luck

[metalworker0]

Think it's a black smith he wants not a machine shop. or both

all the best.mark