Exhaust manifold / catalytic converter leak

[live&learn]

On my 2013 explorer 3.5l n/a I have a leak where the front exhaust manifold and exhaust pipe come together. I found a picture online of where the leak is coming from. although the picture shows its fully welded it appears the factory manifolds are not.

I tried using a product from Advanced auto called exhaust seal, but once it cures it is very brittle and I'm assuming where the leak is there's to much movement causing the sealer to crack. I have tried just the sealant, then the sealant with strands of fiberglass mixed in and lastly the sealant and then 2 fiberglass sheets with the sealant in-between each layer of fiberglass, but it keeps cracking.

I don't want to weld the manifold while its installed and I'd prefer not to take it off and weld it. Has anyone had a leak at this spot on the manifold, if so has anyone had any luck with a high temp sealant or epoxy?

 

[SofaKing95]

Welding is your only option...well, that or total replacement. Those "tapes" and "sealers" are for the most part worthless.

 

[Steve8316]

...a leak where the front exhaust manifold and exhaust pipe come together. I found a picture online of where the leak is coming from.

That's not what you circled, which is the weld joint between the manifold and its flange that bolts to the head.

although the picture shows its fully welded it appears the factory manifolds are not.

Yes, all manifolds are welded there, unless they're cast as 1 piece. Post pics of yours on your vehicle showing why you think it's leaking there. Remove anything you've applied over the leak before taking the pics.

I don't want to weld the manifold while its installed and I'd prefer not to take it off and weld it.

Then take it to a pro.

...has anyone had any luck...?

Don't rely on luck, or what other people have done for their issues. Concentrate on YOUR vehicle, and how to fix it right.

 

[live&learn]

Hey there Steve, you really picked apart my post, I'm glad you weren't able to mark it up with a red pen like teachers did back in the day

That's not what you circled, which is the weld joint between the manifold and its flange that bolts to the head.

Flange is what I meant, not sure why I said manifold. I was at work when I made this post and was rushed trying to send this out. So yes, the leak is coming from where the flange and exhaust tube meet, or very near it.

Yes, all manifolds are welded there, unless they're cast as 1 piece. Post pics of yours on your vehicle showing why you think it's leaking there. Remove anything you've applied over the leak before taking the pics.

I was referring to the pic being fully welded on the outside, this was a picture I found from ebay for an aftermarket cat so thats why it's different than factory. the factory flange looks like there is a tack weld on the side, I'm guessing these are internally welded to reduce turbulence, but without removing it I cannot confirm that. But I would agree with you that they are welded and not pressed in.

I did not take any pictures when I was under the vehicle, I was hoping the chap fix would've fixed the problem so even though I thought about taking pics just in case it didn't work, and I needed to come on here for advice like I'm doing now I didn't. I've always been bad at taking pics when I work on something.

The issue started with a p0430 and p0420. I did some troubleshooting and one of the tests I did was using a shop vac to pressurize the exhaust then I sprayed soapy water on everything and that where the bubbles showed up. the leak is on cylinder #6 only

Then take it to a pro.

First, I'm not taking to a shop to spend a bunch of for something I can do. I wanted to try a cheap and easy fix first before I had to spend a bunch of time on a proper repair. Also, I not the type of person that just pays someone to fix things for me, I take pride in being able to do things myself. And it doesn't make much sense to pay someone to do something that I am fully capable of doing myself

Don't rely on luck, or what other people have done for their issues. Concentrate on YOUR vehicle, and how to fix it right.

I am concentrating on MY vehicle. Like most issues people have with their vehicles, the issues they're having is usually a common issue with that make and model, so I was hoping someone had come across a leak here and were successful with making a repair with a sealant. But I'm guessing a lot of people just take it to a shop and the shop just takes the easy route and says the cat is bad and replaces it. beings as though the cat is not bad and it's just a leak I don't see the point in replacing it.


With all that said, that sealant I used must have cracked again because my check engine came back on so I'm going to remove sealant and weld the crack in the exhaust. I'll be sure to take pictures and post them.