Has anyone ever replaced these exhaust gaskets?

[DigitalFusion]

Hey All,

After installing the copper exhaust donuts, I found that I have a pretty bad leak from both of the gaskets where the Y-pipes connect to the single pipe to the muffler. I've gotta be honest, I am not looking forward to having to get the old gaskets out, and I think putting the new ones in will be even worse! Anyone done this before, and/or anyone have any helpful tips, tricks, or insights? The gaskets I am talking about are #17 in the pic:

 

[APEX 06]

Its a pain in the #*$&@ to. They come out easy but a pain in the #*$&@ to get back in. take your time getting them back in you have to push the pipes back into place with out hurt the new gasket.

 

[DigitalFusion]

yeah, not looking forward to it. Did you expand the pipes somehow when you did it? I was thinking of removing the old gaskets, getting something that is larger than the diameter of the pipes but tapered, and forcing it in to expand the pipes. Just not sure what I could find that would do the trick.

 

[oldguy2]

They make an expander for the auto trade. Probably get it at auto parts store. But are you sure you want to make it bigger?

 

[DigitalFusion]

the pipes have cuts in them to allow the clamps to compress the pipes down around the gasket and Y-pipes, I would think it could work to expand them, and then use a hose clamp or something to bring them back down to size (once the new gaskets are in) so the stock clamps could fit back on?

 

[ViperTurboPete]

My rear pipe was loose and just came out. The gaskets looks fine, but I am thinking of just grinding some of the clamp stopper thing off so I can tighten further. I thought of replacing and yes it looks like a pain in the arse.

 

[DigitalFusion]

yeah, thats pretty much how mine were. I took the y-pipes and muffler out, and reattached the y-pipes. even with the clamps as right as they would go, I could easily pull the y-pipes right out. My gaskets 'look' fine as well, but they are obviously worn. I'd rather just fix it right.

 

[dab102999]

I took mine to a muffler shop to have them "tweak" it out a bit and it split both sides...then i had to weld it...and he was real carefull when he tried to expand it....maybe one of those handheld ones that expand by a ratchet would work better...i put some r.t.v. sealant on mine and that seemed to solve the leak.

 

[DigitalFusion]

krud. that's not very reassuring!

 

[kinger]

I just did this and it was a major PITA! Someone told me to pack the new exhaust gaskets with grease and I did that and it slide on still very hard but it went together. I actually used a ratchet strap to suck them together.

Bad part is the grease stinks like a electrical short for about 200 miles.
Good luck prepare the body for bruises and cuts because you get so hopping mad you start throwing sh** LOL

 

[kinger]

Oh also do NOT bend out the tabs on the y pipe very far, I think that was part of my problem is I bent them out and because its curved it made a indent back IN at the base of the tab, it also slightly cracked that tab in that spot. Its ok once installed but its better to not have that indent at the base of the metal tabs.

 

[DigitalFusion]

can you elaborate on the ratchet strap to suck them together? Im not quite sure I follow that. Also, how did you bend the tabs out? Did you use something tapered, or did you just open them up with a pliers or something?

 

[kinger]

I wouldn't reccomend the ratchet strap only as a last resort. Once your in there you'll figure out real quick where to loop the strap to suck everything together.

I used a pliars, again not reccomended to go to far if at all.

The grease was the best trick.

 

[thrasher]

Replaced mine as well, yes a pain in the #*$&@. Removed the old ones by tapping a flat screwdriver under the gaskets and breaking them apart. Used sandpaper to remove all the old gasket material. Slightly bent out all 4 tabs on each pipe end to get the new gaskets in. Then used a rubber mallet to beat on the muffler to get the muffler pipe to push into the y-pipes. It's a tight fit. I believe I also dropped just the rear of the suspension so I could see what the hell was going on up there. When I did mine, I also had to have the 2 into 1 area of the muffler pipe rewelded as it was severely cracked at the original weld.

 

[ViperTurboPete]

Phew! My pipes slipped out when I went to move my rear muffler back while changing to copper donuts. I thought those gaskets (#17) were gone too. I put the pipes back in, lubed the threads and torqued it hard until the stopper tabs on the clamps bent outward. Now the pipes are sealed well and won't come out.

I can't wait to hear what the sled is supposed to sound like with new donuts (which were completely gone) and the tightened/sealed mid pipes. I guess I just got used to it getting louder and louder and not noticing.