I just installed a new apn header (wow what a pain), and I have an exhaust leak. I poured some seafoam through it and I can see its all coming from the exhaust where it connects to the downpipe.

I'm wondering what is wrong. I installed the new seal that came in the box and tightened the bolts as much as I could with a wrench and an electric impact wrench. The torque wrench wouldn't fit in there with me holding the top bolt.

This is the first time I've installed a header, maybe I missed something here? Help would be really appriciated.

Also, one last thing. The seal had what looks like wrinkles or random grooves it in, like a piece of wood. Is that the way they are supposed to look?

 

It's leaking between the head and the header or the header and the rest of the exhaust?

 

The header and the rest of the exhaust. I can see it come out when I'm under the jeep and its running with seafoam going though it. I tightened it more and it went away a little but its still leaking. I'm afraid any tighter and ill shear off one of the two bolts.

Its lined up pretty straight, maybe 1/8" off from being perfectly straight, not sure where to go from here

 

needs to be straight to seal correctly, you could loosen bolt on side not leaking and tighten up the other see if it get better

 

guess I will keep messing with it if that's all there is to it.

 

also sounds like the gasket might have been junk from the start. i would get a new one. i bet apn will send one free or u could get it from local auto parts store. i had no leaks with mine

 

If the seal wasnt seated quite right and you used an impact wrench on it, that could have torn that seal up a bit. It sounds like you're gonna have to take the headpipe back off. It shouldnt need to be wrenched on that hard to work properly.