Exhaust flange gasket - Phase 2

Installed the flange gasket today. It was a bit of a struggle getting clearance between the manifold and the pipe so I could insert the gasket but I got it on without too much sweat and it all lined up OK. Got it all back together and it's still leaking/noisy.

I found a few things that are probably contributing to the poor seal.

1 - The "bell" end of the head pipe is not very belled or flanged so it doesn't surround the flange gasket as much as I would expect. The top end of the head pipe has been replaced at some time and may be incompatible with the manifold.

2 - The clamp flange (on the head pipe) is kind of weak looking and is deforming some when I clamp things up.

3 - Is it possible that I have a solid flange gasket on the manifold already or could this be a replacement manifold that is a no gasket type? See picture.

I realize that the items 1 and 2 are less than optimum but if I'm trying to put a flange gasket where it isn't needed it's never going to seal. So, does the manifold look like it accepts the flange gasket or is something else going on here.

 

You'll be better off using studs than bolts.

 

I knew something didn't look right when I put the gasket in. Maybe a closer inspection of the header pipe is in order. I'll remove the gasket tomorrow.

Pack Rat -The bolts were what was on there originally. I'm OK on the suggestion but why are studs better?

 

In the overall scheme of things it's a whole lot easier to heat up the nut and remove it from the stud a year or so down the road then trying to heat up the manifold to remove the seized bolts which, all things being equal, will probably snap off in the manifold. Just from my 30 odd years experience.

 

Makes sense to me. I'll have to find some studs around here.

30 years experience! Hard to believe, you look so young in your picture.

 

At some point, Jeep eliminated the (composition or steel) doughnut altogether and made the sealing surface part of the manifold. This is definitely a replacement manifold, whether Jeep or aftermarket (I'd guess aftermarket). They have updated the design to include the sealing surface.

The HELP pegs (Dorman products) should have an exhaust stud kit. Comes with two brass nuts and two studs. They make many different types ... hopefully your FLAPS will have them, or help you find the part you need: http://www.dormanproducts.com/search.aspx?SearchTerm=exhaust+studs

The clamping ring is a generic part - source it from your FLAPS (via Walker) or from your local muffler shop.

Walker may supply the down pipe ... if not, the muffler shop can make one for you. Be aware that muffler shops like to weld-in stuff, so if they replace it, it will probably be a single piece and welded to the muffler. Welding is more reliable than clamps, but forces you to revisit the muffler shop if you have a problem.

 

That picture is from back in my younger, wilder days .

 

I got my entire system(walker) new from rock auto.

My manifold,dated 8/5/75 has the counterbore for the gasket ring still. But I am missing the clamp bracket for the downpipe.