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Discussion Starter · #1 ·
This may be a long shot, but does anyone happen to know off hand what gasket I need between the exhaust manifold and the pipe that leads toward the cat? It's a 1995 Trooper Limited, DOHC.

There is definitely a leak there and has been for a year. Not sure if there is even a gasket there at all, but I will need to pass emissions testing in about a month. I called a few local exhaust shops and none of them want to touch it. One guy took a quick look and said the bolts at that flange will be a problem, and one my be cross-threaded because it looks crooked. He said if a bolt breaks there, he'd need to pull the manifold and would be charging me big $$$. And the usual parts suspects can't seem to tell me what size gasket I need.

Anyone know the measurements, and whether it is of the type that surrounds the bolt holes or one that just slips in around the pipe? Got any tips for getting the bolts off? The location of the darn things makes it tough - really tight working quarters, which is why I tried to take it somewhere before trying on my own. Gotta do something though, this is my daily driver at the moment, and needs to pass testing.
 

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MEphenSean said:
This may be a long shot, but does anyone happen to know off hand what gasket I need between the exhaust manifold and the pipe that leads toward the cat? It's a 1995 Trooper Limited, DOHC.

There is definitely a leak there and has been for a year. Not sure if there is even a gasket there at all, but I will need to pass emissions testing in about a month. I called a few local exhaust shops and none of them want to touch it. One guy took a quick look and said the bolts at that flange will be a problem, and one my be cross-threaded because it looks crooked. He said if a bolt breaks there, he'd need to pull the manifold and would be charging me big $$$. And the usual parts suspects can't seem to tell me what size gasket I need.

Anyone know the measurements, and whether it is of the type that surrounds the bolt holes or one that just slips in around the pipe? Got any tips for getting the bolts off? The location of the darn things makes it tough - really tight working quarters, which is why I tried to take it somewhere before trying on my own. Gotta do something though, this is my daily driver at the moment, and needs to pass testing.
Two ways I know to loosen them are penetrating oil or heat. I just took a bunch out of the rear bumper and hitch of mine without any broken by heating the bolt heads until they just started to glow red with acetylene then letting them cool for a few minutes then taking them out.
 

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Discussion Starter · #3 ·
Thanks for the tip. I've used PB Blaster with mixed success - sometimes it works (better than other stuff), sometimes it doesn't. Do you think heating the bolts in question enough could be accomplished by simply running the engine, given that they are on the exhaust and forqard of the cat, or will it take more than that? This job is making me nervous, but I need to do it and do so without spending $500.
 

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http://www.rockauto.com/catalog/moreinfo.php?pk=121156

is the gasket.

On getting the nuts removed the penetrating oil is good and if possible i would use an impact wrench as well. All of them you can reach with a straight extension and deep well socket.

When you have the pipe out of the way I would use a die or one of the nuts at least to run up and down the threads a few times with anti seize on them to clean and smooth them.

After you get the new gasket in and run it a few minutes, tighten it up again as at least for me they tend to compress a bit.
 

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Discussion Starter · #5 ·
vanduker said:
http://www.rockauto.com/catalog/moreinfo.php?pk=121156

is the gasket.
Thanks a ton! I saw that at O'Reilly and was thinking it was right, but I hadn't taken any measurements and was far from sure. I'll pick up a couple, in case I fudge one up or need to do the other side, make sure I have plenty of PB Blaster, and get at it. I will also definitely hit the threads with some anti-sieze before slapping it back together, and maybe see about an apropriate die.

I feel a bit betetr now, just kinda find a couple hours soon. :roll:
 

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Discussion Starter · #6 ·
Got it fixed! I was worried about the bolts being too rusted to get the nuts off. I soaked them for ten minutes in Pennzoil quick penetrant, then for another ten in PB Blaster, and they came off surprisingly easy.
Had to remove the short pipe coming down from the manifold (I was hoping I could just loosen it and slip the gasket in), and the hardest part was actually the nut and bolt on top of the downstream end, near the y-junction. You can see it, but man that it is a tight fight and hard to get a wrench on. Ended up using a crescent wrench on one end.

My Trooper is now quieter than it has been in over a year, and I presume (fingers crossed, knocking on wood, rubbing a rabbit's foot, and consulting an ancient book of spells) that it will pass the emissions test.

Thanks again for pointing me to the right gasket, and Rock Auto. I picked up some nice plug wires at a great price too, and their shipping took two days, counting the day I ordered! Will deifnitely be using them again.
 
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