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I have an 87 F-150 302. I put headers on it about 1 year ago and ive been having problems with one of them leaking. I just replaced the gasket and retightened all the bolts and its still leaking. What might be the problem?
cracked because of heat or maybe a hole that you did hear at first getting bigger
I had a problem so bad I had to take them off and reweld all the beads they had put on because I put out too much heat causing cracks
Try using two gaskets on each side and get a set of locking header bolts. I've always had good luck with Mr Gasket Ultra Seal gaskets; they're easy to find and relatively inexpensive.
1" header bolts will make a big difference. also if you start your tightening sequence in the middle of the header and work you way out in a cross pattern you will ge a more snug fit as well.
what brand header are you running and did you unbolt the Y pipe before you tried to bolt the header back up?
All excellent suggestions. The only thing I can add is that if you have a binding/torqueing issue with you exhaust system it will flex your headers a lot possibly making them crack, brake welds etc. Make sure your exhaust system has some flex (to avoid binding) and doesn't want to jump to a new spot when it's unbolted from the headers (to avoid torquing).
I doubt longer bolts will be needed if the locking C-clips and washers are installed. In some cases a longer bolt wont even go in straight because of the way the primaries are bent...never hurts to try it though. If you can get longer bolts in, then a regular old lock washer can be used to keep the bolt from backing out.
the reason for longer bolts is to allow for more of the bolt to get screwed in. this will make it harder for them to back out as well especially on the thicker flanged headers