Did anyone had a hard time getting the headers to seal properly where they join with the donut gasket (front manifold) ? i couldnt get it to seal right, its always leaking!! has anyone tried exhaust sealants? do they work?

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

It will seal, you have to maneuver it quite a bit but there is a sweet spot. Bolt the front headers up to the xover pipe but do not tighten them down. Tighten the crossover pipe to the front and rear manifolds and then tighten down the front manifold and it should work from there. That xover is the biggest bitch with these headers....

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2009.5 SBM G8 GT
November 2011 Car of the Month

I <3 zzp's headers.

No three piece swindling to get them lined properly, just two piece slip fit design. Band clamp, some RTV around the edges, and you're done.

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'04 GP CompG - 2.6" junk

OP i've been battling this issue too. i just tried to re-work it today actually. Unbolted the crossover where it connects to the front header(left everything else bolted down) and just tried to reposition the donut gasket between the two and added some sealant. . . . still no luck it still leaks a bit. I really don't want to unbolt the fron header to re-seal it

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Comp G: 3.2-E85-65's-headers-rockers-104's-DHP tune & "other stuff that doesn't matter"

I think that's what I'm gona have to end up doing pretty soon, and I just ordered some GE silicon gasket sealant, its supposed to b flexible, not affected with vibration and won't break down with heat, so hopefully that helps
I tried doin wat u did too, it just doesn't sit right, I had it positioned good before but that was by taking the front manifold out and u pretty much have to force the front mani to go in right again

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

Yea my leak is so small i don't even know if it'd be worth that.

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Comp G: 3.2-E85-65's-headers-rockers-104's-DHP tune & "other stuff that doesn't matter"

i took both the front mani and the cross over out, replaced both donut gaskets and i put the cross over with the front first, put the front on, then bolt the cross over back to the rear manifold, and i think the leak got worse lol, i just bought some sealnt, im gona try that and c how it works

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

Copper rtv that donut gasket and get some grade 8 bolts. I torqued the crap out of mine and never had any leaks.

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

i just got some GE flexible sealant im gona try that when i have a day off
i did torque them good, last time i torqued it too much i ended up breaking the donut gaskets

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

if they where $200 cheaper

i like the SLP knock offs they fit and do not cost an arm and a leg

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater