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Manifold to Y pipe exhaust leak

This is a discussion on Manifold to Y pipe exhaust leak within the Technical / Maintenance forums, part of the General Discussion category; So I noticed an exhaust leak inbetween the manifold and Y pipe on both sides. so I went and got ...

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    Yes A 1999 OBS Abes's Avatar
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    Manifold to Y pipe exhaust leak


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    So I noticed an exhaust leak inbetween the manifold and Y pipe on both sides. so I went and got new gaskets and when I bolted everything back together on the one side its still leaking. Is there a trick to getting those gaskets to seal right??? Its the 61014 fel pro exhaust flange gasket. any help with this problem would be greatly appreciated.

    Thanks.
    1999 Chevrolet K2500 350/4L80E/NP243/9.5" 14B
    3" Body Lift with 285/75/16 Cooper St's on NBS alloy wheels
    Cherry Bomb turbo mufflers
    Auto Meter Trans Temp Gauge
    Nelsons 89 octane Tune
    8' Western Plow

    2001 Polaris Xplorer 400 2 stroke 4x4 - Bone stock

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    Yes A 1999 OBS Abes's Avatar
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    Re: Manifold to Y pipe exhaust leak

    Anybody??? I need to get this back together to get to work tommorow morning.
    1999 Chevrolet K2500 350/4L80E/NP243/9.5" 14B
    3" Body Lift with 285/75/16 Cooper St's on NBS alloy wheels
    Cherry Bomb turbo mufflers
    Auto Meter Trans Temp Gauge
    Nelsons 89 octane Tune
    8' Western Plow

    2001 Polaris Xplorer 400 2 stroke 4x4 - Bone stock

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    Re: Manifold to Y pipe exhaust leak

    Quote Originally Posted by Abes
    So I noticed an exhaust leak inbetween the manifold and Y pipe on both sides. so I went and got new gaskets and when I bolted everything back together on the one side its still leaking. Is there a trick to getting those gaskets to seal right??? Its the 61014 fel pro exhaust flange gasket. any help with this problem would be greatly appreciated.

    Thanks.
    When you tighten the nuts to the studs (there will be 3) you need to tighten them equally. If you give one nut 10 turns, stop and do the others with 10 turns. Keep this going until they are all tight. If you crank one nut too tight, then move on to the others, there is a chance the others won't properly seal.

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    Yes A 1999 OBS Abes's Avatar
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    Re: Manifold to Y pipe exhaust leak

    Thanks man I did what you said and its sealed up nice now. Unfortunately the Bolt flange is falling apart though I think I need to get a new one.
    1999 Chevrolet K2500 350/4L80E/NP243/9.5" 14B
    3" Body Lift with 285/75/16 Cooper St's on NBS alloy wheels
    Cherry Bomb turbo mufflers
    Auto Meter Trans Temp Gauge
    Nelsons 89 octane Tune
    8' Western Plow

    2001 Polaris Xplorer 400 2 stroke 4x4 - Bone stock

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    Re: Manifold to Y pipe exhaust leak

    Quote Originally Posted by Abes
    Thanks man I did what you said and its sealed up nice now. Unfortunately the Bolt flange is falling apart though I think I need to get a new one.
    Good to see it's not leaking - nothing more annoying than that 'ticking'.

  6. #6
    Yes A 1999 OBS Abes's Avatar
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    Re: Manifold to Y pipe exhaust leak

    Quote Originally Posted by tjk1812
    Good to see it's not leaking - nothing more annoying than that 'ticking'.
    lol its been that way for a year I just finally got around to doing it. I thought it was a warped manifold and i didnt have $300 to spend. But I just noticed it was these gaskets last weekend. Im betting this is also why im getting lean codes because the exhaust was leaking prior to the o2 sensors.
    1999 Chevrolet K2500 350/4L80E/NP243/9.5" 14B
    3" Body Lift with 285/75/16 Cooper St's on NBS alloy wheels
    Cherry Bomb turbo mufflers
    Auto Meter Trans Temp Gauge
    Nelsons 89 octane Tune
    8' Western Plow

    2001 Polaris Xplorer 400 2 stroke 4x4 - Bone stock

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    Re: Manifold to Y pipe exhaust leak

    Also...there was a TSB which says to cut 2mm off each of the little feet on the flanges. After a while the mouth of the Y pipe where those damned donuts sit becomes flare and then the feet stop you from getting a good seal on the gasket.
    I did mine recently.



    Howard

    YOU ONLY NEED TWO TOOLS IN LIFE - WD-40 AND DUCT TAPE. IF IT DOESN'T
    MOVE AND SHOULD, USE THE WD-40. IF IT SHOULDN'T MOVE AND DOES, USE THE
    DUCT TAPE.

    98 K1500 Suburban, 4L80E, Whipple SC, Marine Intake, Hydroboost, LS1 0411 PCM.

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    Yes A 1999 OBS Abes's Avatar
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    Re: Manifold to Y pipe exhaust leak

    Quote Originally Posted by Da Burb
    Also...there was a TSB which says to cut 2mm off each of the little feet on the flanges. After a while the mouth of the Y pipe where those damned donuts sit becomes flare and then the feet stop you from getting a good seal on the gasket.
    I did mine recently.



    I ended up having to do that to the drivers side flange. I cut off a little more than you did. Both sides are sealed up great now.
    1999 Chevrolet K2500 350/4L80E/NP243/9.5" 14B
    3" Body Lift with 285/75/16 Cooper St's on NBS alloy wheels
    Cherry Bomb turbo mufflers
    Auto Meter Trans Temp Gauge
    Nelsons 89 octane Tune
    8' Western Plow

    2001 Polaris Xplorer 400 2 stroke 4x4 - Bone stock

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    Re: Manifold to Y pipe exhaust leak

    Yeah...I think I should have actually taken more off.
    Seems to be OK now though.
    If you look at the new, replacement units...there are no feet. The flanges are flat.
    Howard

    YOU ONLY NEED TWO TOOLS IN LIFE - WD-40 AND DUCT TAPE. IF IT DOESN'T
    MOVE AND SHOULD, USE THE WD-40. IF IT SHOULDN'T MOVE AND DOES, USE THE
    DUCT TAPE.

    98 K1500 Suburban, 4L80E, Whipple SC, Marine Intake, Hydroboost, LS1 0411 PCM.

  10. #10
    95 C-1500 Ext. Silverado Bigg G's Avatar
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    Re: Manifold to Y pipe exhaust leak

    I wish this thread was up a few months back because I replaced both of my exhaust manifolds/gaskets and flange gaskets and all went well until trying to get my passenger side flange gasket to seat properly. I finally gave up, removed the pipe, hack sawed off the old springs and bolts and installed new spring and bolt kits on both sides and it finally seated correctly.

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    Re: Manifold to Y pipe exhaust leak

    Quote Originally Posted by Da Burb
    Also...there was a TSB which says to cut 2mm off each of the little feet on the flanges. After a while the mouth of the Y pipe where those damned donuts sit becomes flare and then the feet stop you from getting a good seal on the gasket.
    I did mine recently.



    That's a good tip - wasn't aware of the TSB. Always looking for new info. Thanks.

  12. #12
    Australian Chevy
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    Re: Manifold to Y pipe exhaust leak

    Exhaust System - Rattle/Rumble Noise

    Bulletin No.: 01-06-05-006

    Date: November, 2001

    Subject:
    Exhaust System Rumble/Rattle Noise
    (Replace Exhaust Pipe Seals and Modify Exhaust Pipe Ring Flanges)

    Models:
    1996-1998 Chevrolet and GMC C/K Models with 4.3L Engine (VIN W - RPO L35)

    1996-1999 Chevrolet and GMC C/K Models (Old Style) with 5.0L
    or 5.7L Engine (VINs M, R - RPOs L30, L31)

    2000 Chevrolet and GMC C/K Models (Old Style)
    with 5.7L Engine (VIN R - RPO L31)

    1996-2002 Chevrolet and GMC G-Vans with 4.3L, 5.0L
    or 5.7L Engine (VINs W, M, R - RPOs L35, L30 or L31)

    1996-2002 Chevrolet and GMC S/T, M/L Models
    with 4.3L Engine (VIN W - RPO L35)

    1999-2000 Cadillac Escalade

    1996-2002 Oldsmobile Bravada

    Condition
    Some customers may comment on a rumble/rattle type noise that is audible in the vehicle passenger compartment when the engine is idling, the
    transmission is in Drive and the service brakes are applied. High ambient temperatures and A/C compressor cycling may further aggravate this condition.

    Cause
    This condition may be the result of inadequate clampload on the exhaust pipe seals at the exhaust pipe/manifold joint. The low seal clampload may be
    the result of the standoffs on either one or both of the exhaust pipe ring flanges contacting the exhaust manifold.

    Correction
    This condition can be corrected by replacing the existing exhaust pipe seals with new seals, P/N 15093974, and modifying the exhaust pipe ring flanges.
    The ring flange modification consists of reducing the height of all three of the standoffs on both of the exhaust pipe ring flanges by 2 mm (0.08 in).
    Follow the procedure below:

    1. Following the Service Manual procedure, lower the exhaust system down enough to access the exhaust pipe ring flanges.

    2. Remove and discard the existing exhaust pipe seals.

    3. With the ring flanges slid down the exhaust pipe, mark each of the three standoffs on both the rings 2 mm (0.08 in) down from the surface that
    faces the exhaust manifold.

    4. Grind the ring flange standoffs to the marks established in the previous step on both of the flanges.

    5. Install new exhaust pipe seals, P/N 15093974.

    6. Raise the exhaust pipe into position and hand start the ring flange to exhaust manifold fasteners.

    Notice:
    Use the tightening sequence and specifications shown when installing fasteners in order to avoid damage to parts and systems. If exhaust system is
    disconnected at any location other than at the exhaust seal, gasket and exhaust system alignment may be required.

    7. Following the fastener tightening sequence, gradually draw the ring flanges toward the exhaust manifold seal faces, maintaining the ring flanges as
    parallel to the manifold faces as possible.

    Tighten the exhaust ring flange to exhaust manifold fasteners to the specification indicated by vehicle year and model shown:

    96-02 S/T Truck: 39 lb. ft.
    96-02 M/L Van: 39 lb. ft.
    96-97 C/K Truck (Old Style): 35 lb. ft.
    98-00 C/K Truck (Old Style): 47 lb. ft.
    96-02 G-Van: 48 lb. ft.

    Exhaust Manifold Donut Seal PN 15093974 (Qty. 2)

    Converter to muffler gasket: PN 15051878 (Qty. 1)
    Howard

    YOU ONLY NEED TWO TOOLS IN LIFE - WD-40 AND DUCT TAPE. IF IT DOESN'T
    MOVE AND SHOULD, USE THE WD-40. IF IT SHOULDN'T MOVE AND DOES, USE THE
    DUCT TAPE.

    98 K1500 Suburban, 4L80E, Whipple SC, Marine Intake, Hydroboost, LS1 0411 PCM.

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    Registered User chevyike's Avatar
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    Re: Manifold to Y pipe exhaust leak

    i have a 6.0 2000 nbs, autozone shows a round thin metal ring gasket that goes from manifold to y pipe, gotta tackle in am hope its right. just did manifold gaskets, now need flange gaskets augh!
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    2000 silverado 2500 ex cab 4x4 6.0

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