Ok, Specs are now in my siggy for the truck we are working with.

Here's the question. Recently went with the dual exhaust 'kit'. I removed the middle/midship fuel tank to make room for it, and all in all? The kit needed a few cuts and tweaks...but fit actually pretty well and sounds decent. (job took a few hours, but it went well due to working with new parts)

On the right (passenger side) manifold connection, I think either there was a change...or the supplier made an error with the flange. We did not notice this until after everything was bolted up of course, as the old flange/gasket/connection was in pretty bad shape. The replacement pipe uses a large "Flare" end, which is supposed to mate to the manifold using a normal donut gasket. For what it's worth? The Left side (drivers side) uses a normal little recess pocket that the normal donut fits into just nice, and is sealed up. No packing donut--just a normal donut for a flange setup.

And after we found out the exhaust leaks a bit at that manifold? I took a look at the construction of the old pipe. Yep...You guessed it...Different mounting. The pipe that came out? Uses a packing donut. The pipe actually extends out about 1/4-3/8" of an inch..and uses a large "Ridge" to retain the rear end of the donut packing. The packing wraps around the pipe, and butts up against that ridge. Once secured with the flange, it's a solid sealed connection.

Gonna need some options and ideas on how to modify this so we can get it sealed. Adapters...clamps...oversized "Donuts"... We can live with it for the time being (it's still not going to be on the road for a few more weeks...but I'd like to resolve this before we start driving it).

Just need the options and ideas. And if we have no other options? Might need to call the seller/distrib. and ask for their input. Can't really blame them to much, as the parts listings show the normal flange/donut is used quite a bit..and the packing style donut seems not to be very popular.

Thanks in advance!.

S-

 

Just a Bump. I think we've got it fingered out...but at this point I'm open to suggestions.

S-

 

I'm a little confused Got any pictures of what the pipes look like? Do you mean one side takes a gasket and the other doesn't? As in one side has a ball flange??



And other uses a donut?

 

Near as I can figure this so far. The old pipe did use a flange to hold it to the manifold. The pipe itself has a large "ring/lip". The pipe itself sticks out about 1/2" beyond that lip/ring device and the donut slides over the pipe, and the back end of the donut rests against that lip/ring.

As I was considering this problem, it occurred to me that this is an intentional design. It would retain the donut on the end of the pipe while it was being installed into the manifold. (otherwise it's a real Pain in the rear to hold the donut lined up...butt the flare end of the pipe against it...then move the flange itself into place.. We kept dropping the stinker while trying to aligned it). The old gasket/donut thing had a flat on the end that butted against the lip/ring..and a cone shape that entered into the manifold.

Now the new pipe just has a very short flare end on it. And the donut, while it is 'cone shaped' to enter the exhaust manifold appears to fit correctly--and does fit into the pipe correctly? Due to the lack of the pipe having that lip/ridge? The flange is about 1/2" closer to the manifold then on the factory pipe. (basically it's sitting against the manifold when it's tightened..and still leaky).

Now I'm thinking if this would work. Finding a "donut" of the same diameter, but wider/thicker. If the ridge/lip was on the new pipe? This would be a non-issue, as the flange would have enough space to tighten correctly.

S-

 

A thicker donut should work for you. You can take donut you have now to a local muffler shop. They should be able to match up a donut for you for a few bucks.