Header leaking...

[Stump Jumper]

Just installed a new set of Thorley headers on my 2000 V10. On first trip, had a bad exhaust leak on the drivers side front using normal fiber gasket. Replaced with Ford metal reusable gasket at Thorley's recommendation but still have a leak at the same spot. Header looked straight when it was installed. Have had several people tell me to use Red RTV on the header, letting it set up for awhile before installing header. Has anyone else used and had success with Red RTV on an exhaust leak. Any other suggestions?

[whem2fish]

never had a v-10 but in 30 years chevy and ford street and strip i went to local speed shop and bought mr. gasket would last a year or two now some of my friend would soak the gasket in water before install(i never tried it) dont know about red rtv. on my rv i have doug thorley on a 454 about 20,000 miles and 3 years not leaking yet. is there a chance a bolt is bottoming out

[Stump Jumper]

No the bolt is not bottoming out. I am wondering if the header is not slightly out of true instead. Anyone other ideas?

[TXiceman]

Check the manifold as well as the head surface. It is possible that the leak eroded one of the surfaces. You can try to repair the area with some muffler cement when you reinstall the manifold

ken

[Tom Cook]

I have used red (high temp) silicone sealer on headers, not the best fix but it does work.
CAUTION: Be sure that any sealer you use on the exhaust sysyem states that it is safe for use on a system with Oxygen Sensors! Some sealers will kill your sensors.

[carstud]

I installed the same headers on my 2000 v-10 in are f-53 chassis. I used reflex gaskets and stage 8 locking bolts. I also band clamps at the connection joints instead of the u bolts style clamps supplied. Reflex says they not need to be retightened I found this is not true. I would install gasket with new bolts. Then drive 500-1000 miles. Retighten bolts, install lock locks and clips on bolts. I have no leaks after 10k. I would also use a high flow air filter and install the 5 star tuning sct tuner. I just got back from a 4300 mile trip and averaged 8 mpg at 70-75mph. On are way back in southern California we came up cajon pass which we drove 2 years ago when got are rv. Then we could only due 45-50mph now we could easily maintain 60-65mph it is about a 6% grade.

[Stump Jumper]

When you say "reflex gaskets", I assume you mean the metal gaskets that are basically expandable with multiple accordian like layers around the ports?

[carstud]

My apology should have said remflex gasket not reflex gasket auto type changed it and I did not catch it before I posted it. I purchased mine from www.dougthorely.com which is a reseller of the headers.

[carstud]

Ugh www.dougthorley.com

[Nick-B]

I used the red RTV on the headers on my 460. Works quite well.

I think you do need to closely inspect the exhaust port on the head where it is leaking. Could be cracked in which case nothing will seal it.

[brokeokie]

While I'm not a big fan of using sealer on exhaust systems I have had good success with the RTV copper.When I have to use it I apply it to whatever I am trying to seal,let it set up a little,then tighten it down and let it sit for 24 hrs if at all possible.If I remember right it is sensor friendly.I have also used a grey RTV product that is high pressure but not sure about it's heat capabilities.One other thing you might try if you could find them is copper gaskets.If you have a few tools and a little ability you could just by some sheet type copper and make your own.Probably don't need to tell you this but did you start in the middle and work you way out?Or did you follow a torque pattern of any sort?

[Stump Jumper]

Yeah, I started in the middle and worked my way toward the ends. Used a metal gasket from Ford this time along with Red RTV and so far, so good. Thanks for all of the help and advise.

[HoRotica]

I have had good success coating the cheap white paper gaskets with never-sieze. The metal in the never seize seems to help keep the paper from burning and I have had the bolts back loose without it torching the paper when doing this.

I Have also used the RTV red and no gaskets in racing applications but havent tried it in a motorhome. I wouldnt hesitate to give it a try...

Chris

[Stump Jumper]

After taking it out for a test drive, I have a very light ticking coming from the drivers side. With the metal gasket and the red RTV, is it likely to get worse or will it just stay similar to the way it is now.