Anyone knows if the water and soap spraying or the hose and funnel method works to find exhaust leaks at the manifold to downpipe union? I replaced this gasket with felpro gasket and still get popping at exhaust on deceleration with the msa premium exhaust stock manifold kit

 I think the water will evaporate immediately. I use a 3' - 4' piece of garden hose as a stethoscope. It's a very effective method for sourcing noises. You'll be able to get one end of the hose down by the gasket while remaining clear of the hot manifold.

I guess my leak is still at the manifold to downpipe union. Today i found a very rustes broken stud and my mechanics rachet tool attached to it. Should i consider buying the set of three studs and nuts? Maybe a better quality?

You need a better quality mechanic.

Edit - actually that might not be a broken bolt.  It looks like a ratchet extension.  Still, a good mechanic would have seen the broken exhaust flange stud and fixed it.

Yes, you should get three new studs and nuts and a better mechanic.

Edited May 14, 20177 yr by Zed Head

 Ditto on the new studs, lock washers and nuts. You'll also want to coat all the threads with anti-seize. None has been used on the old studs in your pic. (Shame, Shame) Another possibility to ensure there's no trouble with removal in the future would be brass nuts on steel (maybe stainless) studs. Before you tear it apart, how about clamping the side of the flange with the broken stud with vise grips and listen to the degree of change. Should be easy to reach from above.

been down this route recently. will need to remove the manifold which means removing the intake 1st then the exhaust (at least on a EFI setup) then take to a machine shop and get them to remove the broken stud. Lastly new studs on the down pipe, fix any broken studs in the head (a lot of care and a reverse drill bit with a drill guide). Then a new manifold gasket. If you are ham handed then better leave it ALL alone.

the way to get the exhaust nuts off the down pipe would be to heat with an oxy acetaline torch. No short cuts here. If you don't have the tools or the expertise then better to not try.

Edited May 14, 20177 yr by Dave WM

here is part one of my saga

 

the only thing I would have done different is I would have kept the heat shield in place, its nearly impossible to put back on AFTER the manifold is re installed.

i already order a three set stud with nuts from zcardepot on ebay. Wish i could get a stainless Steel set or something that could hold up more heat. I also ordered a new Felpro Manifold to Downpipe gasket.

Yesterday i checked for leaks on the other unions of the pipes and did not found anything. Car keeps popping on exhaust. Trying to get used to it!

The MSA PREMIUM EXHAUST Kit came with an Xcelerator Turbo Muffler:

http://www.apexhaust.com/product/automotive-light-truck/muffler/xlerator-big-max-turbo-mufflers/

 

Edited May 15, 20177 yr by jalexquijano

Mark's suggestion of using vise-grips to clamp the flange was a good one.  Just for a short test.  See if the popping goes away.

I've previously used the soapy water method to find a header leak. If you already suspect where the leak is, you can apply the soapy mixture when the car is cold. If the exhaust is leaking, it will immediately blow bubbles, as soon as you start it.


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On 2017-5-14 at 3:45 PM, Dave WM said:

been down this route recently. will need to remove the manifold which means removing the intake 1st then the exhaust (at least on a EFI setup) then take to a machine shop and get them to remove the broken stud. Lastly new studs on the down pipe, fix any broken studs in the head (a lot of care and a reverse drill bit with a drill guide). Then a new manifold gasket. If you are ham handed then better leave it ALL alone.

the way to get the exhaust nuts off the down pipe would be to heat with an oxy acetaline torch. No short cuts here. If you don't have the tools or the expertise then better to not try.

While trying to extract the broken stud the extracting tool broke and now my mechanic has to remover the manifold completely. We have noticed that 3 years ago when the air galley was removed the former mechanics did not removed the guides and just installed new bronze bolts to cover the holes. Ill take pictures of them and will post them for your opinion

Edited May 27, 20177 yr by jalexquijano