Mini header eating EGR Gaskets

I've searched for a thread on this topic, to no avail. 97 4WD std cab Tacoma 5 speed 205K. After upgrading my 2.7 cast mani to a used factory mini header I've replaced two EGR gaskets and now am in need of a third. Seems the cork (whatever material) is wearing off leaving only the metal part left to cause a leak. I'm only getting around 10K before they wear out. Anybody else run into this?

 

I've done this mod, without issues. I used all OEM gaskets. Did you?

 

the problem is its not supposed to be a cork gasket, you must have the gasket for the other end of the pipe or the egr to intake side or its just a cheap crappy gasket.

the gasket you need is a stiff heat treated material like bake a lite or ceramic fiber or something.

as mentioned get OEM (copper gasket) to avoid issues or be sure its a heat proof material NOT cork.

I used the felpro gasket and had no issues.

another note is try adding a washer under the nut to each stud in case the threads are not letting it crush all the way down. I needed to do this to the engine side for the new manifold since the cast is much thicker flange then the steel so it washing fully crushing the gasket there. you can tell this if the nut spins on freely then is as tight as it will get as soon as it stops, you should feel at least a little compression to tighten against after the nut is on all the way.

 

I used FELPRO http://www.oreillyauto.com/site/c/detail/FEL0/70961.oap?ck=Search_70961_-1_2392&keyword=#70961.

For lack of better words I said cork (which I knew it wasn't) sorry to be misleading.

I'm confident that the gasket was tightened correctly.

I'll try an OEM gasket, couldn't hurt.

 

maybe the nut is bottoming out on the threads and not closing the gap fully, try using an extra washer to be sure.

I have seen the studs back out a thread or two and cause this