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A couple of months ago I was getting on the express way and all of a sudden I noticed an exhaust leak. It was fine before that. Since I tried re-tightening the bolts. No luck, then I put some new gaskets on (fel pro) no luck. Any suggestions on how to fix this? Is it possible that the header warped or something. The leak is coming from the engine bay, I checked the exhaust system and it ok.
 

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Satyr of the Midwest
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17,734 Posts
You could have warped header flanges. The easiest thing to do is take them off and hold a straight-edge against them to check for gaps. Next time, try some exhaust manifold gaskets for a 1997-2000 5.0L Explorer. They're graphite and very good quality (even the Fel-Pro ones). :thumbup

You may also have an exhaust leak in the air injection pipes and/or check valves. It'd be worth getting a look at things behind the engine to see.
 
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