Exhaust gasket keeps going bad?

2012 CHEVROLET MALIBU
210,000 MILES • 2.4L • 4 CYL • 2WD • AUTOMATIC
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JEFF WAHLQUIST
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I replaced the flex pipe with new gaskets. After a few weeks the gasket were blown out. I then replaced the gaskets again. Now they have blown again. Is there a solution to this?
Oct 24, 2023 at 3:06 PM
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JACOBANDNICKOLAS
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When you install the new ones, is there any rust or damage at the flange where the gasket sits? Also, make sure the flanges are flat and not warped.

I attached the torque specifications below. Tighten them to this specification. If it is too loose, that can cause it to fail. Also, if anything appears to be warped, try using two gaskets.

Let me know if this helps.

Take care,

Joe

See pic below.
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Oct 24, 2023 at 6:00 PM
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JEFF WAHLQUIST
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Turns out the flanges on the exhaust are warped, 2 gaskets won't help. I need to get the flanges flat or weld it.
Oct 30, 2023 at 5:22 AM
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JACOBANDNICKOLAS
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Hi,

Wow, if two gaskets won't work, they must be warped badly. Before you go crazy trying to find someone to machine a flat surface, price a new part. I suspect the cost will be very similar. I just looked up the price for a new manifold (I suspect that is the part that is warped). The OEM part is 113.00. I suspect you will have that in repairing the original one.

It's just a thought.

Let me know if I can help in any way.

Take care,

joe

See pic below.
Image (Click to enlarge)
Attached Media
Oct 30, 2023 at 6:30 PM