My 4.2 NA has an exhaust leak where the pipe connects to the manifold on the passenger side. I pulled that piece of pipe today and discovered that the studs in the manifold have shoulders which limits how far the two hole flange can tighten. Mine was tight and still leaking. Both the manifold and the flared pipe appear to be in good condition. I'm thinking maybe I weld a bead around the top side of the two hole flange so it puts more pressure on the pipe. Or maybe install some kind of spacer between the flange and flared end of the pipe. Thoughts?

 

clean up the surfaces jam copper rtv in there

 

That's a solution I had not even thought about...