A couple of months ago I blew a gasket between my turbo and exhaust manifold....my bad because I didn't check the nuts which had backed off. Fixed that issue but then three weeks ago I noticed the car sounding more like a truck. Long story short, the exhaust manifold was somewhat loose and found that two bolts had broken off. I had torqued one off when we installed the turbo but these two that broke recently were at the other end of the manifold.

I had all the bolts replaced and during this found that the manifold itself is a little warped but with the new gasket and nuts/bolts, things seem to be fine for now. I will have to buy another exhaust manifold however

Are there stronger bolts/pins that can replace the oem ones ? Not sure if anyone else with an aftermarket turbo has had similar issues.

I suspect that there is a shearing effect going on during wot which may be causing this....just a guess.

I definitely am going to keep a close eye on them but I know I'm going to go thru this again and would like to do my homework before that day comes.

Any thoughts ?

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Ottawa, Ontario, Canada
2007 - 2.4 - Black - Hahn Stage 3, Hahn Hi-Flow CAT, Solo SQR-2, Norm's Finned Diffuser & Fenders, GReddy BOV & PRofec-B Spec-II B/C, Autometer Mech Boost & Electric Oil Temp gauges, DDM Two gauge A-Pillar POD & Powdercoated valve & engine covers, Illuminated WR, JPM Centre Console, Arm Rests & Visor Covers, Stubby Antenna
Team Solstice 2008

opjohn
I had the exact same issue about 18 months ago. When I looked at the stock manifold and then the turbo manifold I notice the holes in stock were significantly larger than on the turbo manifold. I also noticed the seperation cuts between each port were also touching each other.

It was shearing that caused this, as such I ended up modifying the turbo manifold by:
- Drilling out all but the two center most ones to match stock
- Recut (sawed) the seperation cuts between each port to provide more clearance (alllow for more CTE issues).

Never had the problem again.

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North Fort Worth Solstice #2020
Mine on: 12/10/2005 from Alan Young Dealership
Color: Deep, Steel/Sand, Hahn Turbo, and other good stuff.

Wow !

So I hit the nail on the head :-) Thought I might have been off base but thanks VIN2020. I'm going to have to look at the stock manifold again and then order a new turbo manifold and follow your suggestion. Alot of work but I can't afford to be doing this every year :-(

I wonder if the turbo manifold design needs to be re-addressed ? Must be others contending with this ?

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Ottawa, Ontario, Canada
2007 - 2.4 - Black - Hahn Stage 3, Hahn Hi-Flow CAT, Solo SQR-2, Norm's Finned Diffuser & Fenders, GReddy BOV & PRofec-B Spec-II B/C, Autometer Mech Boost & Electric Oil Temp gauges, DDM Two gauge A-Pillar POD & Powdercoated valve & engine covers, Illuminated WR, JPM Centre Console, Arm Rests & Visor Covers, Stubby Antenna
Team Solstice 2008

I had the same thing happen to me just a few weeks ago. I had to send my manifold back to Hahn. They did some updates to it and it appears they actually cut a relief in the hole closest to the firewall and put more space between the flanges. Just sent the manifold back to hahn and they took care of it. I would get in touch with Aaron or Bill and see if your manifold has been updated.

Good Luck.

Clear

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View my car domain page http://www.cardomain.com/ride/3062072
Proud owner of Hahn Racecrafts "Soul Food" Solstice and member of TEAM SOLSTICE 2008

Mods

• Hahn Turbo Stage IV with valvetrain upgrades
• Clutch Masters Stage IV Clutch
• Hahn High Flow CAT
• Solo Performance Center Dual Exhaust with Norms Fiberglass Diffuser
• Eibach Sportline Springs
• SSBC Big Brake Kit
• Konig Privat 19" Wheels
• Custom Two Tone Paint
• Razzi Wing
  

I had this same thing happen about 18 months ago as well. I used a rotary grinder to reshape the holes in the manifold to look like the stock manifold and so far so good.

Wow...this does seem to be a bit more widespread than I thought. I'll have to contact them and ask them to send me out a new updated one. Mine is warped and not much use in modifying that one. If they are aware of updates like this, they should let us know.

I just spent a fair bit of money having this fixed and now I'm going to have to do it all over again.

I can do it myself but just don't have the time. This is my daily driver. Anywho....Thanks guys for all your feedback on this....especially clear !!!

I will contact them and see if they have changed their manifold design.

Thanks guys !

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Ottawa, Ontario, Canada
2007 - 2.4 - Black - Hahn Stage 3, Hahn Hi-Flow CAT, Solo SQR-2, Norm's Finned Diffuser & Fenders, GReddy BOV & PRofec-B Spec-II B/C, Autometer Mech Boost & Electric Oil Temp gauges, DDM Two gauge A-Pillar POD & Powdercoated valve & engine covers, Illuminated WR, JPM Centre Console, Arm Rests & Visor Covers, Stubby Antenna
Team Solstice 2008

I have to quit reading items like this. Every time I get ready to do something to boost my car, I hear another problem, not that I don't expect some issues, but this sounds like a major design problem. Well I'll wait and see what happens here.

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2007 Sky, Midnight Blue, May 18 2006. #1303 - MODS- KS Wind Screen, Magnaflow Quad Tips 2.5 C/B Exhaust, SMS Header, Redline Rear Valance,PCM Retune, M1 Wheels, Falken 452 tires

nighttripper,

It is not a major design problem, just room for improvement like any product has.

Sorry to hear you are going to remain on sidelines, and not have any fun with a boosted Sol (I cant imagine life that way). My personal recommendation is call Bill Hahn, and lay out the cash. You wont be sorry.

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North Fort Worth Solstice #2020
Mine on: 12/10/2005 from Alan Young Dealership
Color: Deep, Steel/Sand, Hahn Turbo, and other good stuff.

Thanks for the imput, I shouldn't be waiting to much longer,tuition for my daughter first. then something for the young one ( My Sky)

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2007 Sky, Midnight Blue, May 18 2006. #1303 - MODS- KS Wind Screen, Magnaflow Quad Tips 2.5 C/B Exhaust, SMS Header, Redline Rear Valance,PCM Retune, M1 Wheels, Falken 452 tires

Stock ones are junk, I had mine break also. Go to Summit racing. Summit Racing - High Performance Car and Truck Parts | 800-230-3030 use part no. ARP-400-8024

Good luck