Topic: 20r exhaust gasket always leaks

[Yotaoverland]

Does anyone else ever have trouble with their exhaust gaskets on a 20r? I've replaced at least 3 since I've owned my Toyota.
Should I get a better brand?

[redneckcustoms13]

Stock manifold or header? I had this problem with a hedman shorty header. Ended up welding the flange together.

[emsvitil]

Are the flanges flat?

[kneedownnate]

Are the flanges flat?

Ditto.  That gasket appears to have failed due to one of the flanges being warped.  The 2 options I see are, 1 - remove both the manifold and downpipe and machine both 100% flat, or 2 - buy a smog legal header (if needed where you live) with a thick flange and be done.  Stock manifold is a horrible design for scavenging anyway.

[OVRAROK]

are just removing those 3 bolts, then trying to line up? try removing rubber grommets holding up muffler and at end of tailpipe, then try bolting3 bolt flange together, then persuade the grommets on

[jimbo74]

to me, it seems like your flanges aren't flat.. the way you may be tightening them may also be at fault..... are you able to do what ovrarok recommends? my van has flanges liek that, and I was able to get them all lined up... and both side pipes run ito 1....

[emsvitil]

There's a soft aluminum gasket that's about 3/16" thick used for headers that won't blow out.

[Yotaoverland [OP]]

Thanks for all the replies. It's a pacesetter header. And I never thought about them being flat and mated right.

[Plainview]

I hate that kind of header flange.  Never had much luck with them, even using the aluminum or copper gaskets, they ALWAYS start leaking.  I'd be tempted to cut both flanges off and use a band clamp instead:

http://www.summitracing.com/parts/sum-693250-1/overview/

Ball flanges also work really well.  If the band clamp doesn't work, go to an exhaust shop and have them put a ball flange on it.