Cylinder-head exhaust ports caked with carbon buildup

Exhaust System Repair

Truck Exhaust System Repair — Stacks, Manifolds, Aftertreatment

In short

Exhaust failures range from a cracked manifold (loud and expensive on emissions performance) to a broken bracket holding the DPF housing up. We weld, fabricate, and replace exhaust components at your truck. Manifold and turbo-related exhaust failures get diagnosed in context — sometimes the manifold crack is the symptom and the cause is something else entirely.

Call (931) 561-7736

Based in Russellville, KY · 75-mile radius

Symptoms we look for

You hear
  • · Tick-tick-tick from under the hood (exhaust manifold leak)
  • · Loud bark from the stack
  • · Hiss from the exhaust at boost
You see
  • · Soot trails along the manifold-to-head joint
  • · Cracked stack or DPF housing bracket
  • · Exhaust hanger broken
  • · Black sooty residue on engine components
You smell
  • · Exhaust smell in the cab
  • · Burnt rubber from a heat shield that has shifted

What we cover

  • Exhaust manifold repair and replacement
  • Stack and elbow repair (welding and fabrication)
  • DPF housing and aftertreatment piping repair
  • Exhaust hanger, bracket, and clamp replacement
  • Turbo outlet and bellows repair
  • Charge-air-cooler piping repair (related to but distinct from exhaust)
  • Heat shield repair

How we handle it

Most exhaust calls are weld-and-fix. Cracked manifolds we diagnose first — is it heat-cycling, is it a head problem, is it a stuck turbo wastegate? Then we repair or replace as appropriate. Broken brackets we either repair the broken bracket or fabricate a new one from heavier stock if the OEM bracket has a known failure pattern. Stack repairs and aftertreatment piping are straightforward welding work when the geometry allows. We don't do "tape and clamp" exhaust fixes — when it's broken, we weld it or we replace it.

Parts & warranty

Manifolds OEM (some aftermarket cast-iron manifolds we've tried don't last). Stack and pipe stock from heavy-duty exhaust suppliers in the correct steel grade. Stainless filler rod for high-temp welds. 1-year parts-and-labor on welds and installations.

Related services

Other repairs

Coverage by city

Exhaust System Repair on-site in the cities below. Each link goes to the per-city page with localized response details.

Need exhaust system repair? Call Brennan.

On-site diesel and semi truck repair across the I-65 / I-24 corridor. 24/7 dispatch — the owner answers.

Call (931) 561-7736

Real work, real shop

  • Engine bay during top-end service work

Frequently asked

Why does my exhaust manifold keep cracking?
Heat-cycle stress is the usual cause. If it's a chronic problem on a specific cylinder we look at the underlying cause — over-fueling, stuck wastegate, exhaust restriction downstream. Just replacing the manifold without fixing the cause means we'll be back here.
Can you replace just the cracked section of pipe?
Often yes, depending on where the crack is. Section replacement is cheaper than a full piping replacement. We tell you which makes more sense after we look.
How loud is loud enough that it's a DOT issue?
Federal noise limits aren't tight by themselves but a broken exhaust system upstream of the DPF often triggers DEF/emissions codes, which IS a DOT issue. A broken stack tip is mostly cosmetic and noise. A cracked manifold or broken pipe upstream of the aftertreatment is a real problem.
My stack got hit by a low overhang — can you fix it?
Yes. Bent stacks we straighten if the wall thickness is intact, weld and reinforce if there's damage, or replace if the deformation is past saving. Most stack damage is a 2–3 hour job at your yard.

What customers say

4.7 / 5 from 43 Google reviews

  • “Brennan was great — absolutely hire this guy. I own a local tree company in Goodlettsville and one of my work trucks broke down at short notice. He was able to get there within a day or two and diagnose it. My turbo went out on one of my vehicles — when I went to the dealership they told me the wait time was forever and the process would include taking the cab off, which wouldn't work well with my current setup. Within one day he was able to replace my turbo and get it running so I could get back in business. The job was really labor-intensive but he made quick work of it and it runs even better than it did before. He's now the main guy I go to.”

    — Tyler M.

  • “We've used Blacktop Mobile Repair twice this month, and both experiences have been nothing short of amazing. They run a top-notch operation, and it really shows in the quality of service and professionalism they provide. Jacob, the service tech, went above and beyond to make sure our truck was taken care of. He even drove out of his way to make sure he had the exact part needed to fix the truck and get us back on the road quickly. That level of dedication and commitment is hard to find. As a trucking company, downtime is costly, and having a team like Brennan and Jacob we can rely on makes all the difference.”

    — Matthew P.

  • “I've used these guys in the past for an air compressor installation. Jacob was great. And recently my alternator quit on the weekend. I called Jacob on a Saturday and he helped me find one that I could pick up myself. Both times Jacob was knowledgeable & fair. A few months later — again on a Saturday — I wasn't even in their area and I called again to get troubleshooting advice. They are very good at diagnosing. Was able to pinpoint the trouble. Thanks again guys!”

    — Dennis W.

Read all 43 reviews on Google

Call (931) 561-7736