So it all began with a cracked flex pipe. Replaced the pipe and flange that bolts up to exhaust manifold. Also replaced the gaskets on each end of the flex pipe/ catalytic converter. To the point though. I've replaced these gaskets 3 times already. 2 times with metal gaskets, and once with a paper type material. All three times the manifold to flex pipe gasket has leaked. I've caked it with copper ultra rtv, I've checked the surfaces with a straight edge, ect. I've done plenty of research on the causes and solutions for this issue. Still can't figure it out. Any suggestions would be much appreciated. Thanks

 

Bump. Any ideas guys?

 

Welding

 

So it turns out it was the flex pipe in which I just replaced. Cracked again. Would it hurt to just replace the flex pipe with a solid?

 

The flex is there because the engine rotates during heavy loads

 

I've had my mounts checked because that was my first guess on why the original flex pipe broke. They seemed to be in good shape. Now 3 month after installing a new flex and flange it's cracked again. This is a major headache.

 

What kind of flex coupler did you use and break?

I highly recommend an interlock flex section if you didn't already try one.

 

I just bought a replacement flex section with the 3 bolt flange already welded. Cut the old one off and welded the new one on. I believe it had already been replaced before I bought the car also. What is a interlock flex?

 

http://m.ebay.com/itm/05-06-07-08-09-10-Cobalt-HHR-G5-Saturn-Ion-Direct-Fit-Repair-Flex-Pipe-/201400811018?nav=SEARCH

 

Interlock Flex Section - Exhaust

 

And this is a lot stronger than the normal flex pipes? If so it looks like I'll have to take it to a muffler shop and have them salvage the flange and weld it onto the new zzp pipe.

 

Yes sir.