I drive a 2005 Expedition 5.4L 3V Eddie Bauer 4x4.

I have an annoying exhaust leak I believe is coming from the drivers side manifold flange. I know these years do not use gaskets but have the ball-socket type connection.

I recently had to replace my passenger side catalytic converter (including the entire right side of the Y pipe). All 4 manifold flange bolts broke. I was able to use AP StudFixes (imaged below) to connect 3 of the 4 flange bolts. The 4th (passenger side) I had to drill out and use a nut/bolt configuration as the top of the flange is angled.



The drivers side is held with 2 of the AP StudFixes, which is where my leak is. I believe the leak might just be from old warped metal. The leak is only heard when giving it gas, not at idle. I have no interest in replacing said pipe since it’s attached to the catalytic converter and I don’t have the time/money to do this right now.

Can I throw a donut gasket on there to seal it up?? How about using some Permatex Ultra Copper high temp sealant?

Or does anyone else have any good tips for this? Removing the manifold to machine it is not an option either.

Thank you.


Sent from my iPhone using Tapatalk