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Old 11-08-2006, 09:53 PM
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Fixing Exhaust Leak - Help

So this weekend a buddy and I are going to fix the exhaust leak on the truck. The leak is the gasket that is between the exhaust mainifold and the exhaust pipe, there are 2 bolts connecting the two that are heavily rusted and corroded. If we break these bolts, which is sure to happen, will the whole mainifold have to be replaced? Or can we just pull the bolts out and replace the new ones? Where would we find those, somewhere like ACE Hardware? Im getting a new gasket tommorow, and hopefully there wont be any problems. The only reason im asking is bc my dad took the car to a shop and they were gonna charge 150 to fix the leak, and 600 if the bolts broke. Im not payin that kind of money when my buddy says we can fix it.
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  #2  
Old 11-08-2006, 10:12 PM
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Isn't there 3 bolts in a triangular pattern? Those bolts can be gotten at any local auto store . Make sure to put some anti-seize on them so that isn't a worry if you ever have to remove them again. Actually, if you are putting on a new gasket. Get some spray copper when you get the gasket. Spray down the gasket and the bolt threads. You're good to go then.
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Old 11-08-2006, 10:21 PM
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Quote:
Originally Posted by WraithR/T
Isn't there 3 bolts in a triangular pattern? Those bolts can be gotten at any local auto store . Make sure to put some anti-seize on them so that isn't a worry if you ever have to remove them again. Actually, if you are putting on a new gasket. Get some spray copper when you get the gasket. Spray down the gasket and the bolt threads. You're good to go then.
So no worries about bolts breaking and having to replace the exhaust manifold?
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Old 11-09-2006, 01:41 AM
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If the bolt breaks. Just replace it. You shouldn't have to replace the exhaust manifold unless you tear the flange off. <- Don't do that
Hope that helps. It's been a while since I looked at a stock manifold.
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Old 11-09-2006, 04:04 AM
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not too much worries, just dont go apeshit with the torque, if your header bolts are a little rusty like mine were, youll snap the bolt off in the head, and then if your really lucky, the tap will break in the block like me. but anyway, yeah get some pb blaster or equivelent (wd doesnt work the best) and let that soak before you try the bolts, youll be amazed at the amount it helps. also, you can hop on down to your local autozone and pick up a guide (dont know if it will help here, but its good to have for specs and stuff)
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Old 11-10-2006, 09:37 PM
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Okay, so i went to the local dodge dealer and the advance auto parts and autzone. Adavance and autozone said they had the donut gaskets i was looking for but would have to macth it. Dodge said there were no such things on a 97, the lady even pulled up the diagram for me to look at, the exhaust pipe just connects metal-to-metal to the exhaust manifold. So i have no idea We are going to try anyways and just replace the bolts.
The leak is bad and i dont know if its fixable by just changing the bolts, hope so , the car is running like crap bc of it.
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Old 11-11-2006, 03:25 PM
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So the leak is fixed!!! We cut out the old bolts on the flange and put some new ones and washers on there, tightened er back up an wow, what a difference. The HP is back and my gas is goin up 3-5 MPG. You can also ride in the car and not hear the annoying ticking noise over the radio. The only bad thing is now we've discovered another leak, which isnt nearly as bad. This one is the clamp between the cat converter and the flange(I think). We hope that when connected the flange back to the exhaust manifold we got it on there snug. Dont know about that one, but if anyone has question/problem with the one i fixed and wants details and pics, post and ill do a write up with the measurements of the bolts and such.
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  #8  
Old 12-27-2010, 01:35 AM
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i am having a similar problem as well. on the left side the flange at the end of the header and where the Y pipe begins is totally rusted out. I think i might need to replace the header on that side.

the truck is in the shop right now for another issue, but i told them to take a look at that spot and tell me what they think needs to be done...
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Last edited by blackknight87; 12-30-2010 at 07:30 PM.
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Old 12-29-2010, 05:05 AM
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Can't speak for the 5.2L but I know on the 4.7L there's no gasket between the Y-pipe and exhaust manifold, it's metal to metal like you said. If you ever happen to break the flange or it rusts out, you can buy a "split flange" and bolt it over the y-pipe, then bolt it to the manifold to keep things tight.
When replacing mine, the studs were rusted out so had to have them drilled out of the manifold to put new studs in to bolt to the Y-pipe split flange.
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Old 12-30-2010, 07:30 PM
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Where could i get this split flange? and could you post some pics of your repairs?
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