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Workhorse W42 Exhaust Manifold to Cylinder Head Repair Clamps

Workhorse W42 Exhaust manifold to cylinder head repair clamps

Starting at $21.95, AutoBuffy stocks 3 exhaust manifold to cylinder head repair clamps from SKP. This clamp seals the joint where the exhaust manifold meets the cylinder head, stopping exhaust leaks that develop when gaskets burn out or studs fail. A failed seal lets hot exhaust gases escape near the engine, creating noise, fumes in the cabin, and potential sensor damage.

Signs your Workhorse W42 needs a new exhaust manifold to cylinder head repair clamp

  • Loud ticking or tapping noise from the engine bay that increases with RPM and is most noticeable on a cold start
  • Smell of exhaust fumes inside the cabin, especially with the heater or vents on recirculate
  • Visible soot or carbon black streaking on the exhaust manifold, cylinder head surface, or nearby heat shields
  • Check Engine light triggered by a skewed oxygen sensor reading caused by exhaust gas escaping before the upstream O2 sensor
  • Burning smell from the engine compartment as escaping exhaust gases contact nearby wiring, hoses, or plastic components
  • Failed emissions test due to unmetered exhaust gases upsetting the air-fuel ratio reported by upstream oxygen sensors

Which exhaust manifold to cylinder head repair clamp should you buy for your Workhorse W42?

Repair clamps for this joint come in different band widths, materials, and locking designs — not every clamp fits every manifold flange or stud pattern. The right choice depends on the diameter of your exhaust port opening, the thickness of the mating surfaces, and whether you are making a permanent repair or a temporary field fix.

OEM-spec heavy-gauge steel band clamp
Best for
Direct-fit replacement matching original hardware dimensions
What you get
Precise flange fit, factory torque range, minimal fitment adjustment needed
Stainless steel performance repair clamp
Best for
High-heat applications, turbocharged engines, or long-term durability
What you get
Superior corrosion resistance, withstands higher exhaust temps, longer service life
Universal slip-fit repair clamp with adjustable band
Best for
Shops or owners needing one clamp to cover a range of port diameters
What you get
Wider adjustment range, faster installation, trade-off in precise sealing versus direct-fit
Two-bolt lap-joint repair clamp
Best for
Manifolds where studs have stripped or broken and a full restamp is not yet done
What you get
Bridges damaged stud area, restores seal without manifold removal, bolt-on convenience

Exhaust manifold to cylinder head repair clamps brands we stock for your Workhorse W42

SKP
3 options · from $21.95

Replacing an exhaust manifold to cylinder head repair clamp on a Workhorse W42

Moderate⏱ 1–2 hoursBreaker bar and socket setPenetrating oil (applied well before removal)Wire brush or gasket scraper for surface prepTorque wrenchHeat-resistant gloves

Let the exhaust system cool completely, soak any corroded studs or bolts with penetrating oil well ahead of time, then remove the old clamp and clean both mating surfaces of carbon deposits and old gasket material. Install the new gasket if applicable, position the repair clamp over the joint, and tighten fasteners evenly in a cross pattern to the clamp manufacturer's specified range. Start the engine and check for leaks at the joint before considering the job complete.

Frequently asked questions

How much does it cost to replace exhaust manifold to cylinder head repair clamps on a Workhorse W42?
Parts start at $21.95 at AutoBuffy. A DIY repair costs only the clamp plus basic tools. A shop will add one to two hours of labor, which varies by how accessible the manifold is on your specific engine. Corroded studs or heat-seized hardware can extend labor time and cost significantly.
Can I drive my Workhorse W42 with a leaking exhaust manifold to cylinder head joint?
You should avoid it. A leaking manifold joint lets hot exhaust gases escape inches from wiring, rubber hoses, and plastic intake components, creating a fire and melting risk. Beyond safety, unmetered exhaust gases skew oxygen sensor readings, causing the ECU to miscalculate fueling and potentially damaging the catalytic converter over time.
Will an exhaust manifold to cylinder head repair clamp fix a cracked manifold on a Workhorse W42?
No. A repair clamp addresses leaks at the bolted joint between the manifold flange and the cylinder head — it does not bridge a crack in the manifold body itself. If the manifold casting is cracked, the manifold must be replaced or professionally welded before a clamp will restore a proper seal.
How long does an exhaust manifold to cylinder head repair clamp last on a Workhorse W42?
A quality steel or stainless clamp installed on clean, flat mating surfaces can last many years under normal driving conditions. Longevity drops when underlying studs are weak, mating surfaces are warped, or the vehicle is used in extreme heat cycles. Inspecting the clamp during each oil change takes only seconds and catches early fatigue.
Do I need to replace the exhaust manifold gasket when installing a repair clamp on a Workhorse W42?
Yes, in most cases. The repair clamp restores clamping force, but a burned or compressed gasket will not seal reliably on its own. Replacing the gasket at the same time ensures the new clamp has a fresh, compliant surface to compress against, preventing an immediate repeat leak and saving you from pulling the repair apart again soon.
How do I know which size exhaust manifold to cylinder head repair clamp fits my Workhorse W42?
Match the clamp to your exhaust port outlet diameter and the flange bolt pattern or stud spacing specific to your engine. Use the AutoBuffy vehicle selector with your 2006–2009 Workhorse W42 details to filter to confirmed-fit clamps. When in doubt, measure the port opening and flange width before ordering to avoid returns.

Shop exhaust manifold to cylinder head repair clamps by year for the Workhorse W42

2009200820072006

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