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I think I got the wrong manifold for my Onan 10.0CCKAJ/1E


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  #1  
Old 11-16-2012, 07:44:42 PM
DrCharles DrCharles is offline
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Default I think I got the wrong manifold for my Onan 10.0CCKAJ/1E

I got a nice unused exhaust manifold for my 10.0 CCKAJ/1E, serial D920459200 (that D might be a 0) and had a fun time this afternoon removing the original pipe-thread mufflers (lots of penetrating oil and a big monkey wrench did the trick). Then I went to put the new manifold on... it doesn't fit! The flanges are rotated at a different angle.

http://i1181.photobucket.com/albums/...n/PB160010.jpg

I thought I might be trying to put it on backwards.. but turn it around and it's even worse.
http://i1181.photobucket.com/albums/...n/PB160012.jpg

Apparently all CCK's don't use the same manifold? What have I got here... the only marking on it is a hand-written "1430" in magic marker.

http://i1181.photobucket.com/albums/...n/PB160013.jpg

Or, it just occurred to me, can the cast flanges (that the manifold bolts up to)
be twisted to a different position or are they part of the head?

thanks for any help. Now I don't have any mufflers

---------- Post added at 05:44 PM ---------- Previous post was at 05:33 PM ----------

Sorry, that's "1450" written on the manifold.

I googled "Onan 154-1450" and it comes up for an exhaust manifold for an NH...
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  #2  
Old 11-16-2012, 07:59:08 PM
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Billy J Shafer Billy J Shafer is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

The Flanges don't move. Haven't seen that manifold in a long time.
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Old 11-16-2012, 07:59:52 PM
DrCharles DrCharles is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Yep, that's what I got... three of them on ebay right now and the picture is identical

Now, can someone please verify the correct p/n? My 10CCK parts manual shows either 154-0944 or 154-1212 would work, possibly 154-0998. thanks.
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Old 11-16-2012, 08:50:28 PM
len k len k is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

I suppose you could go to a muffler shop and have them custom weld one up for you, looks pretty simple.
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Old 11-16-2012, 08:54:14 PM
Gunny Gunny is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Made a bunch of them through the years. Pretty easy to do.
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Old 11-16-2012, 10:04:11 PM
len k len k is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Bring them the engine, they will likely have various generic flanges, they'll bolt it on engine, bend and weld a pipe on it, now your spacing and angles are right.
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Old 11-16-2012, 10:08:03 PM
Wayne 440 Wayne 440 is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Yep, make a set of headers for it.
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Old 11-16-2012, 10:18:38 PM
DrCharles DrCharles is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Thanks... I know I can fabricate one, or have one made, but I always prefer to buy the factory original part and bolt it on whenever possible (or if it doesn't cost an arm and a leg which is frequently the case for Onan parts).

There is a used manifold on the 'bay right now (starting at $25) which appears to be the dual-ended 154-0998. I'm tempted to bid on it but not sure if it will clear the "Carrying Frame" which mine came with, mounted on an Onan dolly.

(That's an optimistic name, given that it weighs about 400 lb).
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Old 11-16-2012, 10:53:37 PM
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Why not cut the new manifold about 1 inch above the flanges, twist them to fit the bolt holes on the cast manifold and re-weld them up. I bought a new one for my 5.0 CCK and it looks like it was built for a welder.
http://ebay.com/itm/ONAN-EXHAUST-MANIFOLD-154-0513-NEW-/250575311169

I bought it for $45.00 on a "best offer"
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Old 11-16-2012, 10:57:54 PM
Ed Sparks Ed Sparks is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

That would be my thought also. less than an hour with a cutoff wheel and mig welder, bingo!
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Old 11-16-2012, 11:05:46 PM
mrmegoo mrmegoo is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

I like Motorheads idea, cut the new one & bolt down the flanges to the engine, tack weld the pipe in place, remove & weld it up. Any good exhaust shop should be able to do this & make it look factory. Don't worry much about the pretty paint job on the pipe it won't last very long on a running engine.
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Old 11-16-2012, 11:09:51 PM
David C David C is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

I second Ed's & Motorhead's suggestion. You will spend more time looking for the correct one than it would take to modify the one you have.

David C.
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Old 11-16-2012, 11:14:43 PM
DrCharles DrCharles is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Yeah, I think I'm going to go that route (I can't weld thin pipe worth a hoot but there is a decent welding shop in town, and an exhaust shop too). I just need to check tomorrow if the flanges are actually the same size on the NH manifold as on my CCK, and also spaced the same except for the twist.

Motorhead, are you saying you bought that 154-0513 on ebay and then had to cut/weld the flanges, or did it bolt on without modification?
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Old 11-17-2012, 01:23:41 AM
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Quote:
Originally Posted by DrCharles View Post
Motorhead, are you saying you bought that 154-0513 on ebay and then had to cut/weld the flanges, or did it bolt on without modification?
No, It fit but I had looked at the one you bought too.
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Old 11-19-2012, 02:24:37 PM
DrCharles DrCharles is offline
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

I offered $45 to the same seller, and it was also accepted. Found a pair of "Genuine Onan" gaskets from AnyRVparts.com for $2.56 each (and shipping was only $3.48 too).

So once the manifold is installed and working, guess I'll put the NH one up on ebay (there are three others right now but I just want to recoup my cost, so I can price it lower).
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Old 11-23-2012, 06:11:00 PM
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Default Re: I think I got the wrong manifold for my 10.0CCKAJ/1E

Yet another twist in what should have been a simple project... Anyway, the one that fit Motorhead's" CCK, that I paid $55 with shipping for, does not fit mine (the flanges are too small by about 1/4" between bolt holes, not to mention the smaller pipe diameter).

So I did what I should have done in the first place... cut the flanges off with an air cutoff tool, loaded up the generator on my flatbed and headed to the local welding shop, where for $20 they tig welded it nicely!

Incidentally, although its flanges fit, the NH manifold was also about 1/4" too narrow so I had to heat and bend one of the pipes slightly. Who knows.

Anyhow it's all together, I got a 12" 1-1/4" pipe nipple and a small tractor muffler that is a perfect fit over the other end
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