New project.....exhaust leak problem

[Danny]

Okay guys, I'm pulling my hairs out....what's left of them anyway; here's the deal. Most of you know I've had a cracked exhaust manifold for quite some time now. Well, that problem is solved but in doing so created another one.

I can't get the new exhaust mani to mate to the existing exhaust pipe. Its' metal to, well, metal. I've tried the zinc spray stuff but the leak is to big for that to work.

Does anyone have a suggestion that will get this thing on the road by Wednesday?

Standing by.

[iaccocca]

No expert here, but I sold alot of doughnut gaskets back in the (GM) day. Have you checked if there is supposed to be a gasket of some sort betwixt the manifold and the exhaust?

[RoyBoy]

Maybe some never seize on both sides and on the bolts,it might help seat the two together

[Danny]

No expert here, but I sold alot of doughnut gaskets back in the (GM) day. Have you checked if there is supposed to be a gasket of some sort betwixt the manifold and the exhaust?

ThE donut that they say goes there doesn't fit....not even close. It's METAL-TO-METAL.

And Roy, I have not tried the never seize but it might be worth a try.

[Wrench]

High-temp silicone will work, but only if your vehicle does NOT have an O2 sensor downstream.

[Danny]

So here's what I ended up with. The muffler shops SUCK!!!!

Baxter was a great help, although they recommended a silicon type material, Paul.

What I ended up doing was using some exhaust/muffler compound a friend of mine had used before with good results....not silicone based. I just finished putting it on. Will let it set overnight and see what I have in the morning.

So Paul, what's the deal with the downstream sensor....I do have one.

[Wrench]

I heard silicone will render an O2 sensor useless. Never experienced it myself, so I am not sure how much truth there is to it.

Here is a little info, though you cant always believe what you read on the internet:
http://mr2.com/TEXT/O2_Sensor.html

[Lurch]

If that doesn't work let me know. I have a stuff at work that works pretty good at sealing up stuff like that.

[White trash]

If you are having issues with the collector why not hack it off and replace it with another one? Either a standard 3 bolt flange for cheap from baxters or a ball and socket from summit.

[Wrench]

The issue is with the mating surface between the stock, cast manifold, and the tubing that is flared on the end. I dont think there is any way to "replace" what would be considered the "collector" since it is part of the casting.

[White trash]

The issue is with the mating surface between the stock, cast manifold, and the tubing that is flared on the end. I dont think there is any way to "replace" what would be considered the "collector" since it is part of the casting.

I have no idea about that 4 popper stuff but I thought Danny had a 4.0? That'd mean it is a tube manifold so it can be hacked apart easily.

[TJDave]

Danny has a four banger, but you would never know it.

[Danny]

The issue is with the mating surface between the stock, cast manifold, and the tubing that is flared on the end. I dont think there is any way to "replace" what would be considered the "collector" since it is part of the casting.

I have no idea about that 4 popper stuff but I thought Danny had a 4.0? That'd mean it is a tube manifold so it can be hacked apart easily.

Trashy correct! How about that? Anyone else care to fess up to that? I could just hack it off, or better yet, put a whle new exhaust system on...which I'd like to do. BUT, since I was leaving town this morning at 7:30 for a two month stay in Yuma AZ I needed it fixed yesterday.

So, I put some gray putty type muffler/exhaust goop type stuff and let it set over night....problem solved. Now, after doing that I thought to myself...self I said...what's the torque speck for those nuts? D_ _ _ _ _ if I know so I check....something like 23 pounds and here I am giving her hell...50, 60 easy.

So here's what was happening...it's a theroy because I gooped it. I was over tightening the nuts putting a bow in the flange causing it to open up on the sides causing the leak. I can't prove that now that it's gooped but I'm willing to wager something on it...like the old manifold?