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Chasing Exhaust Leaks

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Old Aug 27, 2022 | 01:21 PM
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desertsherpa's Avatar
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Chasing Exhaust Leaks

I've recently stabbed a new KKD 6.0 longblock into my Econoline, and I've been doing some longer trip testing. And now when I drive it the exhaust coming in the cab is making me lightheaded.
This is probably the only time having a van is an advantage, as getting to the up pipe is really easy.

So I put on a new one piece up pipe, but I"m still getting a leak at the up pipe / exhaust flange, and at the two header flanges.
The turbo, and both exhaust flanges are old and some of the surfaces are somewhat pitted.

When I hook the shopvac up to the exhaust, apply pressure, and put soapy water on these joints, I cannot get them to seal. I've loosened the turbo, readjusted things.
I'm curious if I need to get a new turbo (better sealing surface) and new headers. But that seems a bit over reactive, so I'm coming here to see if any of you have any advice. Or is this amount of leakage par for the course?

TIA!
 
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Old Aug 31, 2022 | 02:53 PM
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I know the exhaust manifold on my passenger side has to be clean and pit free to seal. Always a chore chasing exhaust fumes.
 
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