I may need to replace my exhaust header to cylinder head gaskets, and want to have new ones on hand when I drop the headers. I really don't want to do this job two or three times! Researching this, I've found there aren't many reviews for the various brands/types so thought I would seek out members' experiences.


I'm seeking input on header gaskets, all types, all brands. I'm particular interested in members real world experience with Remflex, Headman, Mr. Gasket, Fel-Pro and Specter (compressed ceramic fiber), as they seem to have at least a few good reviews.


My headers are Banks stainless steel with 3/8" thick flanges.


What's the great, the good, the bad, and the ugly?


Thanks in advance!

 

Fel-Pro. The industry standard.

 

The ones Gibson sent with my headers nine uears ago. Never blew out yet

 

You have to make sure that your headers are flat. Take them to a machine shop to have the flange trued up. There is a reason that the gasket went bad. It's been my experience with headers they get warped and you cant keep the gaskets from leaking. Dont use 2 gaskets thats not going to work. Those locking header bolts work to keep the bolts tight. That also causes a leak and wrapped headers.

 

Thanks for the input, guys!


I am checking regularly and appreciate every response. I definitely will check the header flange for straightness when I drop it, and machine it if necessary. But I want to have my new gasket set "on the bench" before I take anything loose so I can get it back together in a day if possible. These header gaskets have been on for about 8 years and I don't think they will be re-usable even if there is no crack.

Because of a couple of other symptoms, I suspect my cat is just starting to plug off, so I will check backpressure IAW the service manual. Increased pressure may have caused the gasket failure, if indeed that is the cause of the tick I'm trying to silence. I have never seen a complaint about the gaskets Banks supplies with their Power Pack nor have I heard of their header flanges being a problem. So at this point, the pressure test and inspecting the gasket is the next step.


I will look closely at the Gibson gaskets (9 years is exactly the kind of endorsement I'm looking for) as well as Fel-Pro. I insist on their gaskets for everything else.

 

Look for dead soft or multi layer gaskets if available. Mr. Gasket makes an aluminum multi layer reusable gasket. If they have it for application they work. They take up a lot of irregularities in mating surface as well. Biggest thing with headers and leaks is keeping the bolts tight. You'll drop some coin on mechanical locking fasteners but you'll never have to do it again

 

Stock Ford studs i reused when i did my headers. 142k on the truck and headers were installed at 36,100 miles and checked ever 50k till 36,400 miles and then ever year since and they never backed off once

 

SuperDutyScaler, you seem to be the exception on the studs! I installed my headers at 105k miles none were broken or missing when I started but I had three break when I tried to remove them. I bushed the holes in the exhaust manifold down to 3/16", drilled them and used an easy-out. Two on the driver's side were tricky!


They were all replaced with the bolts supplied by Banks. They are all still tight.


From what I am seeing in my research, the thicker gaskets obviously seal gaps better, but the bolts/studs seem to be more prone to coming lose over time with them.


I haven't found a layered soft aluminum gasket set for the V10. The Fel-Pro gaskets are individual--meaning five gaskets to align and hold in place while positioning the header and inserting the header bolts. Not sure I want to try that! They would be fine if I use studs, but I'm leaning towards re-using the bolts from Banks. I'll have to see how they come out. They were coated with anti-seize when installed, most bolts on this truck seem to come out just fine.


I'm still hoping to get a response covering the Remflex gaskets with some time on them.

 

Remflex is the only header gasket I'd ever install on headers ever again. I've burned through fel pros like nothing.

Remflex, practically foolproof.

 

I've found a few generally have good reviews for Remflex. But, I did see one scathing review from a guy who blew through three of them on a V10 Excursion before switching to a composite (Hooker, I believe). There were no details on how he prepped or installed or what fasteners he used, or if he checked his backpressure. And he didn't say if the headers were bargain basement or not. I'm aware that many negative reviews are born of a failure to follow instructions, use the right fasteners, or other "operator error," but I couldn't really tell from what he posted....


What was your application, and how many years/miles have those gaskets been in use? Did you use any type of sealant with them?


Thanks.

 

From my experience with headers this is what I use and have never had any leaks. Felpro MLS and internal wrenching bolts. I always recheck the bolts a few times but never had one break torque.

 

I've got them on my 5.8l for about three years now. Before that I went through three sets two for sure of fel pro and one of whatever came with the hedman headers. I paid a shop to do the first install of the headers. They never recommended coming back for re torquing and I didn't and they burned through in no time, maybe a week or two. I did the first fel pros myself and before I had a chance to retorque them they burned through like first couple runs. The second set I was meticulous about torque and multiple retorques. First mountain pass? Burned through. My buddy who's parents own auto wreckers and has been a wrench himself into high performance modded vehicles told me Remflex. One set, one re-torque and onwards of three years, no leaks. I used new hardware on each install.

 

Also I know Hedman isn't the greatest brand of headers and so maybe some might blame the header but the fact remains those suckers wouldn't stay sealed until I tried the Remflex.

 

Update: I made a test plug and checked the back pressure on my exhaust. Less than 1 PSI! Meaning the gasket did not fail from that. (The shop manual says up to 4 PSI is normal.)


I've sent Banks an email about the failure. I want to see what they recommend. The gaskets they supplied were a composite. BTW, my gaskets have been on there 10 years and 100,000 miles. This is the first problem, so now I'm wondering if I can even do better than that.

 

Whenever you pull those off, make sure the head surface is really clean. A lot of times a blown gasket will make the surface kind of "scaled" looking and the new gaskets wont seal up. Ive always used felpro header gaskets or the one supplied by the header manufacturer.