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Exhaust flange doughnut gasket continuous failure. Ideas why? 200

posted by  someone claiming to be 240snowmobile on  Wed Aug 25 03:43 CST 2004 [RELATED]

So, looking toward the front of the car, the joint fails at roughly the 9 o'clock position?

Assemble the joint without the gasket in place. Shine a light from behind it, and look for any big openings. Take a feeler gauge (preferably one you hate) or something similar and see if it goes inside the joint at various places. This could help you determine the 'high' spots that you might need to grind down if you can't find anything obviously wrong with the rest of the components mentioned so far. A hand grinder would be good. I suspect with the amount of the misalignment or flange distortion or whatever you have, it would take a better part of your evening using 180 grit.

And FWIW, if you have any doubt about the quality of the gaskets you are using, and after going through this as often as you say you have, why not just get one from Volvo? I mean, how much more could they cost?

If all else fails rent a MIG and never worry about it again.





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