I cannot get my damn turbo manifold to header flange (spacer) connection to stop leaking. The gasket looks good, I have tried high temp RTV sealant/gasket maker with the gasket, I've tried using bigger bolts and torqued the **** out of them, I've tried just the gasket itself.

The top and bottom part of the connection seals great, its the sides that keep leaking.

The flange on the spacer is brand new, but is it possible my turbo manifold (bought used) flange is warped? The connection has a TII gasket on it, it is possible that its been removed and reinstalled too many times? Should I try it with no gasket and just RTV?

There are some cracks on the manifold, but not big enough to feel with my nails.

Edit: I'm also not using any washers on the connection, is this my problem?

 

RTV is generally only a temporary method of sealing something. Yes, it is possible your turbo flange could be so warped that it can't obtain a seal. If you're not wanting to spend too much money, you'll need to bend and warp it back straight even though THAT is a temp-fix IMHO.
Fix other cracks as they appear just because they can get bigger and perhaps throw off the real leak-age...
Washers are very useful and you should use them!

 

Yeah screw the RTV, after searching I found it only holds up to ~800*F, far less than typical rotary EGTs. Stuff turns to powder.

I just checked the manifold with a straightedge and it does seem warped. I have absolutely NO clue as to how I would bend it to straighten it out, lol. I will give it to a local machine shop and have them machine it some.

What a ******* nightmare, this is the 3rd time I've removed the turbo. Some bad luck for ya right there How does a manifold even become warped?

 

You can try your luck with a belt sander on each flange to try to get a flat surface if you're cheap but the better option is to have a machine shop deck the flanges.

 

I know your pain, i have this same problem where my exahust connects to the manifold. No matter what I do it leaks. I think that the exahust is bent, i am going to take it by a shop and see what they can do, i know it is quite annoying both the smell and sound.

 

I had the same prob, I went through 5 gaskets b4 I seen this
who ever made my exhaust, made it too long and it was twisted.
had to cut the weld, and about 2 inches from the exhaust pipe, belt sanded the flange and put she together... works...


sorry ^^^^^ I suck at Paint

 

That is about like what my problem is, exact that mine leaks from the top due to being a little to long and bent to much.

 

cut the weld, cut the pipe back, and I know your flange will be bent, I only sanded the pipe flange and it works fine.

 

Take it to an automotive machine shop. They can mill it fairly easily as it's standard procedure. They'll **** and moan about how it's an odd manifold or it's stainless but eventually they'll agree to machine it.