240 - Downpipe replacement and catalytic converter gasket

[billkaz]

Hello all.

Replaced my swiss cheese header downpipe today. Everything came apart fairly well, but putting everything back together was a challenge. Old bolts were very rusty and had a real lousy time trying to find bolts today, so ended up putting the old ones back in.

As for the catalytic converter gasket- The old downpipe had a "floating" flange that connected to the "floating" flange on the cat with the donut gasket. The new downpipe (Walker) has a fixed flange. I reused the old donut gasket, but it is leaking pretty bad. Cleaned the old donut up on the wire wheel and it looked serviceable.

Should I look for a new donut gasket to put in, or go with a flat gasket?

 

[dl242gt]

Generally the flat flange is for the gasket and the rotating flange with the donut. I usually backdate my car to 1990 spec as that is the last year where the flat gasket flange is used on all 240s. I find the gasket is easier to get a no leak connection. The donut is a good idea and seems to work well in the turbos. So, it's really your preference.

 

[billkaz]

Went with the flat gasket and it seems to be working fine.