Leaking

[9723]

..been hearing an exhaust leak where the manifold connects to the catalitic converter section. Took it apart and I see no decernable reason it should be leaking. No bending or warping, no corrosion to speak of.

Only two reasons I can think of:

1. It just needs to be aligned, reseated and torqued evenly.
2. The catalitic is clogged enough to force blow-by thru that fitting.

The '97 has no gasket there and the manifold is a true header (steel tubing) from the factory, and hard to find.

I'm hoping someone has been thru this and has some info....

Thanks!!

 

[rangerbum]

Same problem on my 97 2.3. Until I removed the cat converter, that is. But that Header to down-pipe is a B!@tch to tighten the top bolt.

 

[Hahnsb2]

I welded mine shut when I did my 4.0 swap Of course I only have a foot of pipe after the y-pipe since I'm running a single cat but since no stores had that damn gasket I decided to weld it solid, no leaks

 

[9723]

I fixed it....took it out, lightly hit it with 000 steelwool, put it back in.

I was very careful to line it up snuggly and straight, then I hand tightened the two bolts to the manifold, checking to make sure they were each (on the flange) the same distance from the manifold. Then I torgued each at the same time, starting at 30 lb/ft, then 35, 40 and 45. Tightened the back to the muffler and no more exhaust leak.

I also soaked ( in liquid wrench) and put the wire brush to all the bolts.