GoFastBroncos.com

I have blown out 2 sets of exhaust header gasket for a hedman set on my bronco 5.8. I noticed that the bolts don't stay in and this is prob causing the issue. What's my options here? ( I have torqued them to spec and have tried to rotate them).

Install with tq wrench run motor till hot, re torque, done
PW

Tried that .. Still came loose

Or your gasket is blowing out if it is a cheap gasket then the bolts lose torque. I usually use factory mustang gaskets and arp header studs. Makes putting on cheap headers easier. Also as Paul had stated heat up and re-torque.

Stage 8 bolts with the locking clips always solved my issues with this. If the headers aren't flat and have some stress in them from welding they will be hard to keep tight.

Use percys seal 4 good header gaskets...reusable and I believe are guaranteed against blow out.

I like the others said, remove the header see if its flat, if not surface grind, flycut or belt sand to flat agian. In a pinch remove them and rub the mating surface back n forth agianst the concrete. Any low spots will show as unscratched. Quick n dirty check that works as long as the concrete is finished with few high spots. Or use a straight edge, if you see light there warped. Fix the warp fix the blowout issue.

I blew out 2 gaskets before I checked to make sure the header flange was flat.... not so much. I had and old belt from my belt sander I just and laid flat on a work bench. Sprayed it with some blach primer and sanded it flat like that. A good exhaust shop should be able to do it for you though.

Had a similar issue with a 22R. I ended up using a copper gasket and copper gasket maker.

So here's the update.. Put on extra thick retro flex gasket on drivers side and leak was gone.. Also put on stage 8 locking bolts. Also works great.... However the pass anger side sprang a leak now. Thought ok.. Too easy.. Nope I was wrong.. Gasket fell apart when I pulled it out of package and there is really no room to work for a 280 pound giant. Long story it took 5 hours to remove Exhaust header , break gasket, kick fender in rage mode, go buy cheap set becuase the store didn't have a new good set, install it, and now still have a leak...

shockseals.com wrote:Use percys seal 4 good header gaskets...reusable and I believe are guaranteed against blow out.

This! Stocked at Auto ZOnes... best there is

I have seen a couple warped Headman header flanges that had the same issue with blowing out. Even with a good gasket. Like said by others, check the flange and if needed get it machined flat. I like safety wiring bolts but the locking bolts work well.

On my JBA headers, no problems with backing out with regular header bolts. Evan after 100k miles. I wonder if the flange design contributes to them loosening or what?

Half decent header with a good thick non warped flange, and Teflon tape the header bolts. Works well.