Thread: Exhaust leak while in drive and WOT?

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  1. #1 Exhaust leak while in drive and WOT? 
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    I have what sounds EXACTLY like an exhaust leak. I can only hear it when under heavy or WOT and while driving. I can't reproduce it in neutral and WOT (until it splieks the rev limiter). It sounds like my old lawnmower when the muffler rusted off. It's a loud ticking noise.

    I've inspected my exhaust system, manifolds, cat, muffler etc, and can't find nothing. I live in a very ariod environment so I have no rust at all.

    I've also checked suspension, bearings etc. I'm as suare as I can' that it's exhaust.

    It's a little louder from the driver side and also sounds like it's coming from the engine area.

    Any ideas?
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  2. #2 Re: Exhaust leak while in drive and WOT? 
    Poppin 'em thangs mechguy's Avatar
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    What exhaust configuration do you have?

    Edit: Notice you have manifolds so I assume stock.
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  3. #3 Re: Exhaust leak while in drive and WOT? 
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    All stock (exhaust), 138k miles.

    During the exhaust notes, the car performs perfectly. I pulled all of the plugs and all are pristine (plus I wanted to make sure one wasn't loose and causing the exhaust leaks). No chugging, no misfires, nothing else weird.
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  4. #4 Re: Exhaust leak while in drive and WOT? 
    Moderator dsmuts's Avatar
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    gasket from the dp to catback?
    98 GTP modded 1.9's, sd headers, 3.4", zzp 1.0 230K miles scrapped.
    04 Comp G zzp stb's, UMI ta's, Speedbuilt sways, bully flo heads, XP, zzp headers, fsic, thrasher shift kit, 60#, 2.6" corsa 2.5", Inferno hood
    01 gt z7 turbo tep trans zzp motor
    08 g8 gt cam exhaust 11.87@118
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  5. #5 Re: Exhaust leak while in drive and WOT? 
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    There is no gasket issue. It's perfect (between the two flanges).

    There is a flex joint between the DP to cat (past the flange, cat side) - it seems to be in tact, but I can't tell.

    I'm wondering if excessive engine movement (stock upper mounts, very slightly rotted) cause the engine to twist under load and open the flex joint.

    I can't see any damage with the joint - but I also can't see if when the engine has twisted (like under load).

    I'm stumped - I may record and post as it's very annoying.
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  6. #6 Re: Exhaust leak while in drive and WOT? 
    Moderator dsmuts's Avatar
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    seafoam it and you'll be able to see where it's leaking at
    98 GTP modded 1.9's, sd headers, 3.4", zzp 1.0 230K miles scrapped.
    04 Comp G zzp stb's, UMI ta's, Speedbuilt sways, bully flo heads, XP, zzp headers, fsic, thrasher shift kit, 60#, 2.6" corsa 2.5", Inferno hood
    01 gt z7 turbo tep trans zzp motor
    08 g8 gt cam exhaust 11.87@118
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  7. #7 Re: Exhaust leak while in drive and WOT? 
    The Boss Iceman6669's Avatar
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    Quote Originally Posted by dsmuts View Post
    seafoam it and you'll be able to see where it's leaking at
    Thats the TRUTH!!! I just seafoamed mine and it smoked like a jonesing crackhead.
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  8. #8 Re: Exhaust leak while in drive and WOT? 
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    The seafoam idea was a stroke of genius.

    My car billows smoke from the rear exhaust manifold (of course).

    My plan is to pull it this weekend and see what I can see. I can always weld it back depending on what I find. I can't tell if it's from the mani itself, a gasket or what.

    Any advise/infpo regarding pulling the back manifold? How long does it take etc?

    It looks like something I can knock out over the weekend.
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  9. #9 Re: Exhaust leak while in drive and WOT? 
    Turbo is the way to go. BillBoost37's Avatar
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    Easiest way to pull the manifold is to remove the downpipe and wiggle it out the tunnel hole from below. If needed lower the subframe 2-3 inches at tha back to give you more room.

    Beyond that.. a deep ball pivot snap on socket with a long extension and air tools is the easiest way I've found to pull the bolts.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  10. #10 Re: Exhaust leak while in drive and WOT? 
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    I don't have air tools (worth a crap).

    I assume you access the mani bolts from above, or is it easier from below after you remove the DP (with a real long extension)?

    I'm going to put it on stands tonight and check it with Seafoam again. All I could confirm last night was that it was coming from the area between the back of the engine and firewall.

    I don't know for sure that it's a cracked mani - it might be something with the DP or....? I'm going to look at it from underneath and see if I can better pinpoint the source.
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  11. #11 Re: Exhaust leak while in drive and WOT? 
    Moderator dsmuts's Avatar
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    you can get a new flex welded in last time i did that i got new exhaust from the cat back and all together it was $150
    98 GTP modded 1.9's, sd headers, 3.4", zzp 1.0 230K miles scrapped.
    04 Comp G zzp stb's, UMI ta's, Speedbuilt sways, bully flo heads, XP, zzp headers, fsic, thrasher shift kit, 60#, 2.6" corsa 2.5", Inferno hood
    01 gt z7 turbo tep trans zzp motor
    08 g8 gt cam exhaust 11.87@118
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  12. #12 Re: Exhaust leak while in drive and WOT? 
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    The car has almost 140k miles on it - I just bought a new cat.

    The flex connection had completely failed. I will post a pic later - the interior portion (a sleeve) has come off.
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