I just installed a new catalytic converter and one piece muffler/tailpipe assembly on my 94' 22RE but I evidently didn't install the gaskets correctly because there is a leak between the header and the cat.

This is the tailpipe/muffler (Bosal 268225) :

http://www.rockauto.com/info/Bosal/D...l?08443950.jpg

and the CAT is a Walker 16360.

The Walker CAT included the round type gaskets, however, gaskets that came off the old exhaust were the flange type, and I have new ones of those too.

My question is:

Which gaskets do I use (round, flange, or both)? A gasket needs to be used between the header and the CAT and between the CAT and the tailpipe.

Thanks for looking!

 

I just put a Magnaflow in my 90 pickup, it was a catback so as for the header gasket im not sure but I used the round gasket for the cat and tailpipe fitting. I made a gasket out of my old tailpipe which was a flange and it fit perfectly so Iput them both on but it leaked pretty bad. So, I took it out and kept the round one in and it sounds perfect and there is no leak at all. Good luck!!

 

I went with the round crush gasket and it did the trick! Unfortunately there's still a leak where the headers meet the exhaust manifold. I had a shop install new headers and I have a sneaky suspicion that they reused the old manifold gasket -- it looks pretty bad! How hard/involved of a job would replacing that gasket be?

 

You may try tightening the nuts a bit to see if that helps. If it hasn't been too long the gasket may still be good and if it gets quiet, just replace the nuts with new ones.

New nuts should always be used when replacing the gasket. The nuts are a locking type- either are split and crimped or are slightly oval so they bite on the stud. Once they've been installed and removed they lose the ability to lock and will back off with vibration.

Also, make sure, if yours is the 22re, that you have the pipe support coming off the lower bell housing / transmission. It'll help keep flexing off the header to help keep the nuts from loosening.