Mani Gaskets replaced. Still have exhaust leak. - Jeep Garage - Jeep Forum

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Old 03-19-2017, 10:38 PM
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Mani Gaskets replaced. Still have exhaust leak.

Thanks for taking the time to read my post.
My 05 WK Hemi with 98k miles, has developed an exhaust leak.
We just replaced my CATs with 2 new ones due to one being completely empty. Upon cutting out the old CATs we must have shook loose or broke the passenger mani bolts. I know these have manifold gasket issues so I went ahead and had them both replaced with good Percy 4 layer gaskets and new studs... During replacement my mechanic said only the passenger side was leaking but I opted to have them both replaced and have the manifolds milled down flat due to them being warped.
I thought this would stop the DRIVER side "chuffing" during acceleration exhaust leak noise im getting... but it didn't.

The mechanic is very trust worthy and I did go for a ride with him after the gasket replacement and he couldn't figure out where the leak was coming from.... he momentarily blocked the exhaust exit and I listened for hissing and found none.
I did see old gaskets so I know they were replaced.

So my question is.... could it be the EGR?
It's that annoying sound coming from the driver side that only the driver can hear next to trees or walls. Not at idle or deceleration. And I can hear the MDS make it even worse.

So EGR?
Retorque the crappy manifold to mid pipe flange?
The EGR is probably due for replacement anyways but I can't imagine it would make this much noise....

Any ideas would be great because this is NOT the Hemi tick.

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