Exhaust Gaskets Leaking

[Dyer13]

Does anyone else have an issue with exhaust gaskets not working? I replaced my gaskets twice now in the past year. They work for about a month or two then they start leaking again. I even had a guy who makes custom exhausts take a look at it and he couldn't find a good reason it keeps leaking.

I'm to the point where I'm about to take the entire line off past the headers and weld every seam.

 

[GSLENK]

honestly, If you never plan to upgrade, that's not such a bad idea. I would practice removing the full system that you plan on welding before actually doing it, just to make sure you can deal with it if you have to. would you be welding or someone else?

did you try using double gaskets? (idk if thats really effective at all...)

Does the header to cat joint leak?

 

[jcart953]

I did before i upgraded the exhaust (pipes in picture). I knew Mine were rusted to hell but didn't realize how bad until I sea foamed the car. I originally tried sanding down some of the area to smooth it out but it was just to bad and leaking everywhere. Anyway if you haven't you could try using a sealant with the gaskets to better seal everything up because if you do weld it will be a PITA to get off if you ever decide to change your setup.

 

[XiKeiyaZI]

What sort of gaskets are you using? If you're using metal/aluminum/copper over the crush material then try a generous coating of Copper spray which you can pick up at any local parts store.

Also keep in mind that metal expands with heat and cooling cycles. Try replacing the gasket, running it for a short bit, and then retightening the flange where the gasket is.

 

[romeen]

It might be the nuts and bolts loosening up. Try using a lock nut, Nord-Lock washer, thread locker, etc. and see if the leak still develops after awhile. You can use some Permatex Ultra Copper RTV on the gaskets to help get a better seal.

http://www.permatex.com/products/Au...mum_Temperature_RTV_Silicone_Gasket_Maker.htm

 

[GSLENK]

If you are feeling really ghetto, and the other really good ideas dont work, you could wrap it in that cheap exhaust wrap tape, and then wrap that in exhaust wrap or something. may be a hair cheaper than welding (if you dont have hookups) and still isnt so permanent that you cant take the exhaust apart again.

 

[Dyer13]

I used the one-time use crush type of gaskets. I don't think the bolts are loosening; I used lock washers and doubled up on the nuts.
I guess I'll just drop it out and see what it looks like. I have some of the high-temp copper stuff, I'll try that first and then see what happens. If it comes down to it, I'll be welding it myself--I'm a skilled welder, although not by trade. I have access for a lift, so it shouldn't be hard to pull the whole thing out at once.
I guess it could be just that it's rusting. It doesn't leak at the header, just at the catalytic converter. I'm just not totally convinced it's a rust issue, because I replaced the whole exhaust last year (because the old one rusted out beyond repair), and it shouldn't be that rusted yet.

 

[romeen]

Another option is a Remflex gasket. IF INSTALLED PROPERLY they work extremely well (based on my own personal experience as well as research). Install instructions are very specific with regard to torque values and crush thickness of the gasket. The uninstalled gasket is fragile and can easily break if dropped.

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[Dyer13]

Thanks, I'll check them out. I hate to see other people having issues with their exhaust, but I'm glad to see I'm not the only one. Leaking exhaust really kills the swagger.

 

[bryanwheat]

It is either a warped flange or the bolts backing out. With a good straight flange and a decent gasket it should last for years.