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Exhaust Leak Help Needed

Discussion in 'Early CJ5 and CJ6 Tech' started by Gregory Plouff, Sep 17, 2019.

  1. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    I’ve replaced the gasket between the exhaust header and the downpipe and I’m still getting a leak. I’m had it off many times tried some different sealants but it leaks on both sides. I’m afraid to tighten it up anymore I don’t want to snap the stud off in the cast-iron header
    Is there a donut style gasket that might work better at sealing it?
    I’ve search the forms but came up with nothing. Thanks for any help
     
  2. Sep 17, 2019
    timgr

    timgr Jeepin' Nerd 2020 Sponsor 2019 Sponsor

    Medford Mass USA
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    F134? Always post year/model/equipment with your question, or put it in your signature file.

    So it has a flat gasket from the factory, and you are using it in the factory manner? If it leaks, that means the flange or the manifold face is not flat. I'd take it loose, and get down there with a machinists ruller and measure those parts for flatness.
     
  3. Sep 17, 2019
    Dave B

    Dave B Frankenjeep '67

    Northern Minnesota
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    As Tim suggests info. and pictures would help, without that it is simply guesses to what you have.

    Is this like the down pipe you speak of? And, if so is that where it is leaking?
    [​IMG]
     
  4. Sep 17, 2019
    PeteL

    PeteL Member 2020 Sponsor 2019 Sponsor

    Hills of NH
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    Maybe a misalignment in the exhaust pipe is forcing the gasket surface out of parallel contact... ?

    You could try bolting it up at the manifold with just the down-pipe floating free, and the rest of the exhaust disconnected. If the down pipe doesn't align with rest of the system at it's tail end, heat and bend them until the joints all align without distortion or stress.
     
  5. Sep 17, 2019
    fyrmn

    fyrmn Member 2020 Sponsor 2019 Sponsor

    High Desert AZ
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    My F134 Application. I had the same issue. Eventually had to remove the exhaust manifold so I could work on it. What I thought was clean, once I removed the manifold there was old gasket build up that needed cleaning. "Project creep" as usual
     
  6. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    I made a copper gasket the same as the flat gasket. I’ll probably try a flat gasket on each side of the copper gasket and see if that works.
    Thanks for the ideas, I may have to try some heat.
     
  7. Sep 17, 2019
    timgr

    timgr Jeepin' Nerd 2020 Sponsor 2019 Sponsor

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    Your TSM will have a torque specification for the flange nuts. Also, your local muffler shop can remove any broken studs in situ with the oxyacetylene cutting torch. They'll heat up the broken stud, and one touch to the O2 blasts the stud out. Sounds strange, but I've seen it done. Supposedly quite common.
     
  8. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    Hopefully I don’t break the stud. I do have a local muffler shop close by but I’m being stubborn and trying to figure this out myself
     
  9. Sep 17, 2019
    Howard Eisenhauer

    Howard Eisenhauer Super Moderator Staff Member

    Tantallon, Nova...
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    BTDT.

    Factory pipes have a welded flange & the pipe extends up into the manifold. Muffler shops wil by default swage out the end of the pipe with a loose flange as your pic shows.

    I ended up slipping a short section of next size down pipe in the the exhaust pipe with some stick out at the top into the manifold, no more issues.

    Exhaust Pipe Gasket Recommendations?

    upload_2019-9-17_13-54-57.png
     
    Last edited: Sep 18, 2019
  10. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    That sounds interesting I’m going out to the garage now and see what I can come up with.
     
  11. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    8483EE12-039C-4BD3-ADA0-359547BC2B4D.jpeg 8483EE12-039C-4BD3-ADA0-359547BC2B4D.jpeg Made a bottle holder (or beer can) for this Jeep
     
  12. Sep 17, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    Back together with a sleeve, copper gasket with regular gasket each side. High temperature RTV silicone between each layer. Will let it cure 24 hours and see if it works.
     
  13. Sep 17, 2019
    timgr

    timgr Jeepin' Nerd 2020 Sponsor 2019 Sponsor

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  14. Sep 18, 2019
    Rick Whitson

    Rick Whitson Detroit Area 2020 Sponsor 2019 Sponsor

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    Maybe you should take the manifold off and check it out for flat, it may need to be ground flat??? I had to drill out three broken studs in my head and replace them, I used brass nuts and anti seize on the threads this time. Good Luck
     
  15. Sep 18, 2019
    Gregory Plouff

    Gregory Plouff New Member

    Fraser MI
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    Ok I’ll get some muffler cement, thanks for the tip
     
  16. Sep 18, 2019
    47v6

    47v6 junk wrecker! 2020 Sponsor

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    Sealants and goo are not the answer. As posted above you either have misalignment, something is not flat or a cracked manifold.
     
  17. Sep 18, 2019
    Howard Eisenhauer

    Howard Eisenhauer Super Moderator Staff Member

    Tantallon, Nova...
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    You'll never get a seal to the manifold with a swaged out pipe like the OP has, the manifold just wasn't designed to work that way.
     
    47v6 likes this.
  18. Sep 18, 2019
    PeteL

    PeteL Member 2020 Sponsor 2019 Sponsor

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    x2.
     
  19. Sep 18, 2019
    47v6

    47v6 junk wrecker! 2020 Sponsor

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    If it doesn’t look like this pic, as Howard says, it’s not gonna work right.
     
  20. Sep 18, 2019
    Howard Eisenhauer

    Howard Eisenhauer Super Moderator Staff Member

    Tantallon, Nova...
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    FWIW I didn't require any sealant after I added the interior pipe. If you examine the the manifold you'll find that the bottom part out the outlet is wider than further up- the factory exhaust pipe fits into the wider part & the tension on the pipe flange from the bolt/stud flange forces the pipe to seal on the shoulder of the hole where it narrows down- the pipe flange shouldn't even contact the manifold flange.
     

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