I can't imagine I am the only one that might be going thru this but here goes. I am having to replace the doughnut gaskets for the exhaust flange between the manifold and down pipe once a year. They keep blowing out and creating a leak where the 2 parts meet. Anyone else having a problem like this? I can't believe I am the only one. What do you think might be causing this? The truck is not running lean / hot. I physically looked at both pieces in our machine shop and checked the flatness of both surfaces. The last time I put it together I had it out of the truck and made sure everything was tight. Any suggestions? This is getting old, and I hate sounding like a old VW Beetle when driving down the road.

 

is everything staying tight? maybe use some lock washers under the nuts, my trucks have had problems with the nuts or studs working loose and blowing the gaskets.

 

buy a header

 

I finally had to jam-nut my flange bolts. Only way to have kept them tight.

 

Everything is staying nice and tight. And yes I have added both lock washers, and double nutted (thought they were backing out). Oh and they are the OEM gaskets (not aftermarket).

Elton I'd gladley buy a header as soon as you send the $300+ my way, since I don't have the money for it, and I'm having a hard time justifying the expenditure on a truck w/ 250k miles on it. So I was trying to fix the existing equipment.

 

Are all your hanger brackets in place? Specifically the one off the bell housing?