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Sealing Technologies

Basics of Fel-Pro® Exhaust System Gaskets

Keeping Noise and Gases Under Wraps

Designed to carry away harmful gases that are created during the combustion process, the exhaust system not only keeps dangerous gases from entering the cabin but it also "cleans up" the gases before they are released into the environment. While an exhaust system leak doesn’t involve fluids (except some diesels using DEF), leakage can cause excessive noise, affect emissions, or allow exhaust gases to enter the cabin area. Fel-Pro® provides exhaust system-specific gaskets that help deliver a reliable seal.

Fel-Pro Exhaust System-Specific Gaskets

Because exhaust system replacement gaskets aren’t installed onto pristine surfaces but onto imperfect surfaces in the repair environment, they must withstand heat and motion as well as compensate for corrosion and warping.

Fel-Pro exhaust system gaskets are designed to effectively seal exhaust system joints and surfaces, especially those sealing surfaces that are no longer perfectly flat and corrosion free. Through rigorous research and development, Fel-Pro engineers design, validate and approve its exhaust system gaskets so you can install them with confidence.


Exhaust Pipe & Flange Gaskets

Fel-Pro offers a wide variety of application-specific exhaust flange and exhaust system gaskets. These include flexible expanded graphite packing gaskets (that keep a tight seal on flexible pipe-to-manifold joints), graphite-faced steel core gaskets for flange-to-flange connections, and embossed stainless steel, “ring style” gaskets made of Fel-Ramic® material or graphite. Fel-Pro also offers high temperature alloy (HTA) exhaust gaskets for some turbo applications.

Exhaust Manifold/Exhaust Flange Bolts-Fasteners

Thermal expansion and contraction of the exhaust system can fatigue the exhaust flange fasteners or shear off fasteners in the cylinder head and cause exhaust leaks. The fasteners can become corroded and the threads can become poorly defined, losing strength and clamping force. If a fastener is sheared off, the remaining fastener must be removed and a new one installed.

If worn fasteners are reused, they can possibly fail. Fel-Pro exhaust flange fasteners ensure a tight flange seal at the pipe joint. Some application-specific exhaust flange fasteners have a proprietary coating that helps resist corrosion and feature self-locking nuts, while other exhaust systems use springs at the bolted joint to allow for some flexibility within the assembly. These should also be replaced as they weaken over time from heat and movement. Reusing these springs will not provide the proper clamp load to effectively seal the exhaust joint.


EGR Gaskets

An important component for controlling emissions, the EGR (Exhaust Gas Recirculation) valve reduces nitrous oxide emissions by sending exhaust gases back into the intake manifold where they’re introduced into the combustion process to lower combustion temperatures. A leaking EGR valve gasket, and in some cases the exhaust gas feed tube, can allow exhaust gases into the engine compartment and unwanted air into the intake manifold as well as into the cabin area. Replacement of these gaskets is necessary during EGR system service.


Catalytic Converter Gaskets

An important part of the exhaust system is the catalytic converter which may use gaskets to seal its inlet and outlet joints. On some vehicles, the catalytic converter is now part of the exhaust manifold so it’s critical that the exhaust flange gasket provides a tight seal and doesn’t allow outside air into the exhaust system before the catalytic converter.

Exhaust leaks before the oxygen sensor(s) and catalytic converter(s) allow oxygen into the exhaust system can skew the 02 sensor(s) and the catalytic converter; this can affect drivability and tailpipe emissions and may trigger a Check Engine light. The gaskets used to seal the catalytic converter joints can be flat style gaskets made of stainless steel, embossed graphite, or Fel-Ramic materials. Some joints may be sealed with “ring style” gaskets made of Fel-Ramic or graphite. Fel-Pro also offers application-specific fasteners to provide proper clamp load to these assemblies.

Learn more about Fel-Pro quality gaskets that are specifically designed for the repair environment, find your car part, or find where to buy your auto part today.

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