V-8 Exhaust Leak

[DougS]

Anyone have a similar problem? '97 w/40,000 mi. has an exhaust leak on passenger side. Sounds like it could be coming from the flange where the header connects to the pipe leading to the converter. Also heard that some have had leaks from the EGR tube. Is this a tough repair? Cost? Thanks in advance.

 

[Rec]

Hey Doug, my suggestion would be to get some Motorsport headers to replace the crack prone manifolds. I found them (headers) to be quite affordable ($260). My neighbor had a bad manifold and it cost almost $500 for the part and labor, and it may crack again. Good luck!

 

[Brian97V8]

EGR strikes again

Doug,

A little background info. I have a 97 V8 with about 36,000 on it. Last Feb or March I had to have my EGR replaced. The leak was really bad when the truck was cold or I pressed on the gas. Not sure how much it will cost you. Mine was at the tail end of the 3y/36,000 when I had it replaced. I had to pay I think around $60 but I know the dealership covered most of the cost. As with yours mine sounded like it was coming from the passenger side.

 

[DougS]

Brain,

Thanks to you and Rec for your responses. I think that I will begin with the egr valve as it seems to be the less expensive option. I would like replace the factory headers as I've read on this board they are not the best quality, but that will be left for another time. Have a great holiday.

 

[65Matt]

DougS-

Please keep us posted on what works. I have a 96 with the same problem, an exhaust leak that comes from the pass. side. Also, I am actively seeking an alternative to the SVO headers (some people have claimed they arent very good).

 

[Brian97V8]

Doug,

I also am looking to get new heads but with the hollidays right around the corner they are going to have to wait. For my money thought I would have to say it is the egr.

 

[65Matt]

STEEDA! Steeda sells stainless steel headers for the 5.0 for $250 bucks! This is one great deal!

(Nevermind, I just found out they sell the Ford Racing Headers. Darn!)

[Edited by 65Matt on 11-22-2000 at 09:46 AM]

 

[DougS]

I should have posted this a long time ago...forgot about this thread, but my problem turned out to be the tube running from the EGR valve to the intake manifold. $50.00 part, not too bad. I hope all of you other V-8'ers
are fortunate and don't have to deal with headers and intake gaskets.

 

[youl luz]

mine is doing the same thing...the leak is at the EGR tube(76K miles)..im going to try to change it out this weekend..does anyone have a source for the headers?

 

[YamahaRick]

Originally posted by youl luz
does anyone have a source for the headers?

www.gefracing.com

 

[miahmoore]

I have the same exhaust leak problem. I took it to the shop and the front 2 passenger side header bolts were loose. They were tightened but the problem occured again. Does anyone know the reasoning of this? And if so would it be benificial to purchase new headers?

 

[MSTNGGUY88]

You can't just run any header on these things guys. You need to see if you have the GT-40 or GT-40P heads first. The GT-40P require a P-specific header which Mac sells for around 250 and it is a very good set. If you have the regular GT-40 heads then you might get away with regular headers. I have never heard of the original headers cracking. They are not cast manifolds so they normally don't craqck like the old manifolds would. Newone on me. I think they may have taken someone for a ride when it was just a collector gasket.

 

[rustytr]

Originally posted by DougS
I should have posted this a long time ago...forgot about this thread, but my problem turned out to be the tube running from the EGR valve to the intake manifold. $50.00 part, not too bad. I hope all of you other V-8'ers
are fortunate and don't have to deal with headers and intake gaskets.

Excellent, glad to hear it wasn't the headers that is a pain in the arse if it was.

 

[miahmoore]

how can a person find out if they have gt-40 or gt-40 p heads? Why would exhaust manifold bolts be coming loose? Thanx for the repies.

 

[Jason_25]

I think you have the GT40P heads. Only the '96's have the regular GT40 heads. (I think)

 

[65Matt]

I thought this thread went down with the NASDAQ, but I guess not.

Anyway, to follow up: I did purchase the SVO headers, and they fixed the problem. They were a great fit and easy to install. Ford even includes new bolts and gaskets! Just make sure you have a good variety of sockets and extensions!

Unfortunately, the 'P' headers are hard to impossible to find. I understand they do not make them anymore.

 

[miahmoore]

65matt, I found GT40P headers. You say that it wasn't difficult to install them? How long did it take for the install?

 

[MSTNGGUY88]

All you have to do to know which you have is look by the #1 spark plug. It sis stamped in the head right there by the bolt. It will either have GT-40 staright across it or GT-40P diagnal. Hope this helps.

 

[MSTNGGUY88]

They aren't hard to put on. That is why you don't use regular headers on P heads, That would be hard to install because the P heads have a different angle and position for the spark plug so regular headers will hit the plug and could cause probs. Yes they do make them. MAC and Ford Motorsport are the only 2 I know of though.

 

[GAEXPL]

Thank you guys for all this information. I've been fighting with the dealer for the past 60k about the pinging sounds.

I finally pulled the manifold to check the gasket myself over the weekend and found that the pipes were split, only thing holding the front two to the rest of the exhaust was the heat shields.

As I was looking for info about replacement headers, I cam across this forum! Talk about a stroke of luck.

It looks like the SVO headers for the GT-40 stock heads on my 5.0 should be the correct fit for replacement.

Are there any aftermarket headers that fit the same with the stock exhaust?

I was starting to think I was going Crazy as no tech could give me the answers I found with this site and my own tinkering.

Thanks for the input!