Question. Gasket, manifold to exhaust pipe(s)

[Eugene]

03 Ford Expedition, 5.4 ltr engine, 4 wheel drive.

Is there a gasket between the exhaust manifold and the exhaust pipe?

Reason I'm asking is that I'm getting different opinions - - and it's probably 50 years since I worked on a Ford exhaust manifold to exhaust pipes.

There appears to have not been a gasket(s) between the manifold and the removed exhaust pipe/y pipe/catalytic converters.

The exhaust manifold has a bowl base and exhaust pipes have a reversed bowl shape to match the exhaust manifold.

The gasket provided with the catalytic converter kit does not fit.

[Rick Spivey]

I can't answer your question specifically, but I do know that certain exhaust systems were without gaskets, and had the configuration you describe. It allows some movement but seals fairly effectively when tightened.

Edit, I just checked Rockauto.com and they don't list a manifold to pipe gasket; good indication there is not one.

[Eugene]

Thanks Rick.

Local auto parts old guy said no and then checked his parts catalogs, still no. Did spend a couple additional hours on the internet seeking a positive answer. None found. Did find a name for the gasket.

Will go ahead and finish assembling the exhaust system tomorrow. Guess I will find out if the exhaust leaks and I need flange gaskets.

Guessing son and I will spend around 5 hours removing and installing the catalytic converter Y. Had to spend an hour Dremel grinding off a rounded over manifold nut. Other big problem was getting hands in and around "stuff", a more suitable word, to disconnect the sensors. Did have one sensor we could not remove from old system. Local auto parts store had one on hand.

5 hours of shop time, save $1000-. Works for me.

[Eugene]

Finally got the Expedition's exhaust installed. No gaskets between the manifold and exhaust pipes.

Turned out that the exhaust manifold studs had been replaced. The right side of the exhaust pipe did not fit over/past an enlarged area in the studs. Dremel to mill out the exhaust pipe flange a bit.

Got the exhaust installed and tried to install the sensors. Front sensor on right side, no room to install. Sensor location was off by about 1/4 inch.
Removed the exhaust. Purchased a nut to fit the sensor. Drilled hole in pipe at a new location. Welded on the nut and welded the hole in the old nut shut.

I think we installed and removed the exhaust pipes 5 or 6 times. Guessing, we have about 10 man hours involved.

[tst]

exhaust studs are a common replacement on that engine up here in the North , they rot away and break off in the head, worked many years for Ford and did a ton of them

[Eugene]

exhaust studs are a common replacement on that engine up here in the North , they rot away and break off in the head, worked many years for Ford and did a ton of them

I think the manifold studs were replaced when we installed a new engine 4 years ago.

Actually it wasn't a difficult job. Other complaint was that an impact wrench was used to install the maniflod flange nuts and a couple of lug nuts.

[Eugene]

Son took a load of scrap metal to scrap yard. Received $300- just for the 03 Ford Expedition catalytic converters.

[Dale Finch]

Tell him not to come NEAR my Expedition!!!

[Eugene]

Tell him not to come NEAR my Expedition!!!

Thanks for the invitation. 2 minutes, $300-. Expedition is high enough off the ground to slide under. Next time I'm in your area I will bring my sawzall.

[Dale Finch]