Cast Exhaust Manifolds

Does your engine tick on a cold start, or can you smell exhaust in the engine bay? A cracked manifold is a typical cause. We bring together cast exhaust manifolds for petrol and diesel engines in, for example, Ram, Ford and Chevrolet/GMC – for you who need to replace a worn manifold with a durable solution.

What a cast exhaust manifold does

The manifold collects the exhaust gas from the cylinders and routes it on to the rest of the exhaust system. A cast manifold typically has thick walls that can withstand heat and vibration, but repeated heating and cooling can over time cause cracks or warping. This often shows up as a ticking noise, soot marks at the flange or an exhaust smell.

How to choose the right manifold

In this category you will find, for example, cast manifolds from BD Diesel for Dodge/Ram, Ford and Chevrolet/GMC, among others. Fitment depends on several things at once:

• Engine and model year – e.g. 6.7L, 6.4L, 5.7L Hemi, 3.5L Ecoboost or 6.6L Duramax.
• Side – on V engines, the driver and passenger sides are typically sold separately, so check for DS or PS in the product name.
• With or without catalytic converter – some part numbers have the catalytic converter integrated, which can affect emissions requirements and inspection.
• Connections – flanges, sensor ports and any turbo connection must match your car.

Installation and approval

Use new gaskets and preferably new bolts or studs, as the old ones are often rusty or stretched. Tighten to the manufacturer's torque and sequence, and re-torque after the first heat cycles if the instructions recommend it. Whether the part can be approved for inspection depends on the product and the car – especially for versions with a catalytic converter – so check this for the specific part number. If you are considering headers instead, you can compare with other exhaust manifolds in the parent category.

Frequently asked questions

Do I need to replace both sides on a V engine?

Not necessarily, as the driver and passenger sides are typically sold separately. However, if one manifold is cracked, the other may have been exposed to the same heat and wear, so it is worth inspecting it at the same time.

How do I spot a cracked manifold?

Typical signs are a ticking noise on cold start, an exhaust smell in the engine bay or cabin, and soot marks at the crack or flange. A leaking gasket can cause the same symptoms, so inspect both the manifold and the gasket.

What is the difference between a cast manifold and headers?

Headers – manifolds with separate tubes for each cylinder – are typically built with gas flow in mind. A cast manifold is closer to the original design and typically focuses on durability and fitment. The choice depends on your project.