BD Pulse Exhaust Manifold Install

I found an exhaust leak between the head and exhaust manifold on my 2005 Dodge Ram 3500, 5.9 Cummins Diesel. After consulting with my mechanic, I decided to replace the stock manifold. I have always liked BD products, so I went with the BD Pulse. During the install, I ran into a number of minor inconveniences that cost me effort and time. I thought I'd talk about them.
The casting is a two-piece design, which I have been told will not leak at the joint and will not crack or warp. Leakage was a concern for me, since I have a BD exhaust brake installed, which increases exhaust back-pressure in the manifold when in use.
After installation, I am happy with the BD Pulse manifold. It was a bit of a headache getting into place, though. Insufficient clearance around some of the bolt heads and mounting studs was problematic.

[@trxcummins7388]

you went with BD because you like their product but it seems like a piss poor design to me. I'm guessing they don't claim that it is a direct bolt-on.
After all that do you notice a difference between the manifolds?

[@tthenrie]

None of the after-market manifolds claim performance gains, other than quicker spool-up of the turbo. I noticed that as well on my stock turbo, but as for hp gains, I didn't notice any. The problems I had were not due to design flaws, but more like finish flaws. I just wish they had clearanced a couple areas for bolt heads or provided appropriate allen-head bolts. Seems like they could have done that. Other than that, it is a direct bolt-on. Again, this was on my 2005 Dodge 3500. On other years and models the problems I experienced may not be issues at all.

[@ChubRock3]

I had the BD installed by a shop about 8 years ago. I've always had the 4 mounting nuts slowly back off with heat cycles. Finally going to replace the gasket between turbo and manifold today. Thanks for the video. Glad to know I'm not the only one having difficulty with the clearance for the two top nuts on the passenger side of the turbo. Not trying to take the whole turbo out, just need enough clearance to slip a new gasket in there. Your video helped me visualize my efforts.

[@jamesboldshasta8488]

hope you turbo housing is not cracked. I've seen a couple that have. The leak between turbo and exhaust flange on the side opposite the black. if you replace the gasket and still get a leak you need to remove the turbo and exhaust and really inspect the turbo housing. This really shows it ugly face if using an exhaust brake.

[@austinhills5062]

Crows foot on a torque wrench would work to torque those

[@kenuber4766]

Looks to me like the BD exhaust manifold does not fit all that well. Having to make your own tools and all the problems..."No Thanks"!!

[@wheyez1]

Wow, turning a socket, wouldn’t it been easier to cut the bracket and reattach ( weld it) in position for the upper bolt?

[@tthenrie]

Nope. I could have cut and welded the bracket, but a minute on my lathe to alter the socket was quicker and much easier than pulling out and setting up my welder.

[@bahalp3241]

Does it sound different?