The manifold is a forged steel part. It had two welds that had cracked - #1 and #4, an the flange rim had also rusted away on at least one area. They had to fight tooth and nail to get one bolt out - it was between #1 and #2 under the header tube and down behind the head near the firewall. The hex bolt head was very shallow and it got very hacked up. They managed to cut the washer out and that relieved the pressure, and the bolt finally came out.
I also have a leaking rear muffler (which was overshadowed by the header leak) and I failed the emissions test - because the CPU was "Not Ready" due to the erroneous O2 sensor reading. I'll drive it 100+ miles and it will pass, I think.
I'll find out if my FE gets better. I have to wait until I get the sticker to put my video mirrors back on, but so far the coasting is better than it was before with my beat up skirts and strakes.
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