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Old 13-04-2015, 19:39   #1
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Repair Ford Lehman Exhaust Manifold?

My 1973 vintage Ford Lehman 120 HP Diesel needs repairs. The exhaust manifold has developed a hole at the exit to the elbow, lower side. Can anyone advise if these manifolds can be repaired? Brazing or Welding?

If so can it be repaired in place - since the hole is accessible and visible at the exit of the manifold.

Hoping to salvage my cruising season!

Thank you!
Bruno
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Old 13-04-2015, 19:49   #2
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Re: Repair Ford Lehman Exhaust Manifold?

If its like the ones on my Dad's DeFever they are cast iron. You need to find someone who can weld cast iron. Not an easy task in some locals. Thats the only way to do it correctly.
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Old 13-04-2015, 20:11   #3
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Re: Repair Ford Lehman Exhaust Manifold?

I had the exact same problem with the 4cyl version. A common issue with Lehman, apparently. On advice from a lehman specialist I took my manifold along to a machine shop. They ground out all the faulty material, then rebuilt using a technique called metal spraying (whatever that is). It is done at very high temperature likely to warp the manifold, so they took a shave across the face to ensure a true surface. End result was a manifold as good as new..

Lee
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Old 13-04-2015, 20:15   #4
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Re: Repair Ford Lehman Exhaust Manifold?

It would really be better to replace it. I would try:
American Diesel at 804-435-3107. Bob Smith who owns American Diesel was one of the engineers on the Ford Lehman products. Bob and Brian can answer questions you don't know you have about these engines.

or Bomac Marine in Georgia
Tel: 954-766-2625 Toll Free: 866-419-6363 info@bomacmarine.com

I've had great, fast service from both operations.

It is possible to weld cast iron but if it has rusted through one place there are most likely other thin areas that may go at any time. I would not try to weld in place. If you must try welding I would try to find a tech. school with a welding instructor that may look at it as a challenge. I had an exhaust elbow with the water injector welded once when there were not any currently in stock for my engine. The MAN did a masterful job. He asked if it hat to be gas tight as the old cast iron was very porous. I said yes and it was stressed by high temp. gradients also. In order to be sure it was gas tight he covered a large area with high temp. brazing. More than $70 worth of brazing rod was used on a part that was around 20 square inches of area. He did it as a favor for a friend (and to prove to students that it could be done) and the materials still cost me around $100.
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Old 14-04-2015, 06:59   #5
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Re: Repair Ford Lehman Exhaust Manifold?

Quote:
Originally Posted by LaVida View Post
My 1973 vintage Ford Lehman 120 HP Diesel needs repairs. The exhaust manifold has developed a hole at the exit to the elbow,

If so can it be repaired in place - since the hole is accessible and visible at the exit of the manifold.

Hoping to salvage my cruising season!

Thank you!
Bruno
How about drilling the hole out and tapping the thread to a pipe size and installing a plug?
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Old 14-04-2015, 08:22   #6
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Re: Repair Ford Lehman Exhaust Manifold?

A repair will be a gamble and as we all know, failure can and will occur at the absolute wrong time. The best course is to replace it. Our FL 120 is a great engine. But I would not consider repairing the manifold. Heating and cooling will stress any repairs you make. So why take a shortcut? Chuck
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Old 14-04-2015, 09:03   #7
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Re: Repair Ford Lehman Exhaust Manifold?

LaVida

I also have a vintage (from 1978) Ford-Lehman 120HP on my boat. I have resisted suggestions from my shipyard (Hinckley's) to "upgrade" to a Yanmar or Volvo Penta. I've resisted these suggestions for the past 15 years, because that old Ford Lehman is simple and reliable (as long as she has air and fuel - she runs!). But as an old engine some things wear out and need replacements - and the weak spots seem to be the heat exchanger and the exhaust system. However, these are not in-frequently found on eBay.

Bottom line here, you may find it cheaper and less stressful to replace the exhaust manifold than attempt a repair - which I understand can be tricky and may fail.

In addition, darylat8750 offered an excellent suggestion. I have called Bob and Daryl Smith a few times over the years. They are knowledgeable and always helpful.

There is a knock-off to the Ford Lehman 120 - Ford Saber 120. They used to be in Florida. You may want to do a websearch. They used to use the Ford 120 engine for their conversion (now they use the Perkins 120 if I recall correctly).

Older boats within Grand Banks Trawler community are frequently powered by Ford Lehman 120's and have had active web communities. I have occasionally gotten onto their "chat rooms" (even though I have a sailboat) and they have been very helpful in the past.

I'm sure that you know, the Ford Lehman is basically a marinized Dorset British truck engine and many old tractors in the UK and elsewhere are powered by this engine; meaning that parts are readily available - just not at, say, West Marine.

Hope any of this helps.


Pat
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Old 14-04-2015, 09:18   #8
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Re: Repair Ford Lehman Exhaust Manifold?

If it is cast iron braze welding is best,fusion welding C.I.is more difficult i had C.I.pulley assembly on my lathe with bad crack many years ago still going strong. Better if manifold be removed,person who does this repair will need at least oxy gas gear.
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Old 14-04-2015, 10:38   #9
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Re: Repair Ford Lehman Exhaust Manifold?

I had one made for my 225 turbo for $400.00 last October. Now it's stainless
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Old 14-04-2015, 11:24   #10
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Re: Repair Ford Lehman Exhaust Manifold?

Hey LaVida,
I too have a vintage Ford Lehman in my Hudson Force 50. I found a Lehman specialist who has been worth his weight in cast iron when it comes to service:

Bomac Marine- Ford Lehman Engines Parts, Remanufacture and Service

He has cleaned and re-tipped my injectors and provided many parts as they wear. He offer to rebuild Lehman's at a fraction of the price of re-powering and recommends it since they are just such reliable and good engines.
Regards,
Capt. Rick
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Old 14-04-2015, 13:21   #11
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Re: Repair Ford Lehman Exhaust Manifold?

Ford lehman repair ressources for BC :

new parts: Industrial Engines on Annacis Island

repair,maintenance reingeneering :PM Marine / Paul Meyer in Steveston..

Paul have been working solely on ford lehman for so long...he also used to work for Industrial Engine and Ford back then...he does magic...he will give you the right answer and right option rightaway

good luck
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Old 14-04-2015, 15:09   #12
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Re: Repair Ford Lehman Exhaust Manifold?

JB weld will hold it together while the new one is on order
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Old 14-04-2015, 16:31   #13
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Re: Repair Ford Lehman Exhaust Manifold?

Go along with darylat8750 and others above, I live in Australia and my 73 CHB has original 120 lehman with 11000+ hours, have purchased parts from Bob Smith in Kilmarnock VA and with shipping is cheaper than local suppliers in Aust, a phone call is well received at American Diesel and info is priceless (no charge) Lehman manual about $20 at last purchase.
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Old 14-04-2015, 17:09   #14
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pirate Re: Repair Ford Lehman Exhaust Manifold?

I have a 1973 80 hp ford lehman and replaced the same man. sleeve several years ago while sitting in the Dom. Rep. Go to the American Diesel in Kilmarnock Va. They will treat you right and it is not all that difficult. I am a woman captain and did the job myself. Well, --- my husband was still alive and he handed me the tools.

By the way I also replumbed my fuel system after the stand pipe broke and it works great - even thou several well meaning friends said it would not work. I also bleed my system in 30 seconds or less - no muss no fuss. If you want to know what I did give me a shout
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