Brand New LCE Header leak :(

Hi Guys,

First post here. I have gained lots of great insight through TacomaWorld, So I need to ask you guys for some tips.

I recently got an LCE Header to help make life going up-hill a little easier for my 2.7 2011.

I took it to a local shop, gave them the kit, and had them do the install. 3 days later, what I thought was typical burn-off ended up being an exhaust leak coming from the header.

When I tested it with soap water and reverse air flow through the muffler, I found a big leak with bubbles coming from all around the top and rear of the kit ( See Photo ).

I brought it back in. The shop took it off, and reinstalled it, only to have the same issue.

LCE thinks it's because of a damaged gasket during install. Also, my stock exhaust and manifold were fine with no issues or leaks ever.

Any advice is much appreciated. Thanks!!

 

I would take it back off, take a straight edge to the head and the LCE header flange to see if they’re straight. If those both check out, then you probably just need to get a new gasket. I have reused my stock gasket without issues before though, so I am wondering if something else is amiss

 

Whereabouts are you located? If in central Texas Id be happy to assist

also do you know what kind of gasket they used? A multi layer steel one like stock is gonna be what you want

 

Thanks for the reply, Im in Northern Nevada unfortunately. LCE provided a gasket in the header kit...and they suspect it could be damaged from the shop install. I have another gasket from them coming in. Thinking I'll have another shop check it out, inspect and reinstall with a new gasket. Hope that would work, don't know what else it could be. The chances of an un straight edge on one of their headers seems pretty unlikely perhaps>? Seems like anyone whos wrote about them had no issues with the mod.

 

I agree, the gasket is more than likely the culprit, but it won’t hurt to confirm the flanges with a straight edge. It’s typically the other connection that causes exhaust leaks from what I’ve seen. It might be a good idea to replace the down stream gasket where the collector meets the mid pipe too since it has to come out again.

 

I had one installed about a year ago, no issues.

Bet it's the gasket.

 

On my Doug Thorley header for my 4cyl they recommended that I use the stock exhaust manifold gasket

 

Did you replace the studs? LCE recommends replacement of the studs too. I'm just curious as this is on my list of future mods.

 

Follow up-

2nd mechanic/shop had no luck either. Gaskets were replaced, everything. When I reached out to LCE again, $500+ in labor later, I find out there could be a production issue on the header....I'm sending it back for a refund and am unfortunately just going to call it a loss.

All parts including the studs were replaced in this attempt

Stock parts are now back on and I have never been happier to have my old truck back. The one mod I wanted to do is now axed, I will be a stock soldier from here on out I believe.

 

Well this is concerning for me. I did notice a couple days ago that I couldn't add the header to the cart. I wonder what has happened recently that would make such a drastic change in the quality of a product that was always aces before.

 

I will admit that their customer service is pretty solid regarding the issue. They also say they will be rolling out new production and it should be ready to go in at least 6 weeks. Now my question is, do I bank on the new builds and try again, or just leave it alone...

I had planned on doing a before and after video on the feel/performance too...

Will update if anything else eventful unfolds from this.

 

Nope never replaced the oem exh manifold studs , and as I mentioned I took the advise of Doug Thorley customer service tech and used a Toyota exh manifold gasket instead of the header gasket and it's been leak free

 

This is the header I have from Doug Thorley

http://www.dougthorleyheaders.com/t...4runner-short-tube-(dual-outlet,-w-egr)_15772

 

Here's the Doug Thorley header for your 2011 4 cyl

Unfortunately it's out of stock !!

http://www.dougthorleyheaders.com/t...oma--4runner--prado--hilux-tri-y-header_15770

 

Well it looks like LCE must have had some real issues with the equal length tube headers. Their "new" offering is no longer equal length, as a matter of fact they look a lot like the Doug Thorley headers.

 

Guessing the flange wasn't flat. Machine shops charge like $20 to surface something like that, but it creates a lot of heat and can burn off any coating

 

Wow, that sucks big time. I love my equal length version, shame they dont make them anymore

 

With any style header by doubling up header flange gaskets this will an insure a leak free seal . Using high quality header gaskets from Remflex , Mr Gasket or Felpro and using alumna seal style design material will guarantee a leak free seal

 

Yeah, it really is a bummer. That's been on my wish list for quite a while. I just don't think it'd be worth the money or effort to install a header without the benefits of equal length tubes...imo.

 

Update-

LCE was really helpful. After working it out with them, there was some kind of issue with the weld on the header I ordered (isolated flaw, I just got unlucky). They pulled what they had, and I believe they inspected them all...then did a new production run of the header and sent me the first one (tested and built by their main guy). Great customer service. They stand behind their product.

Install went smooth. No leaks this time!

My thoughts on the header:

Solid solid design and build quality. Just holding it and comparing it to the OEM. Wow.

Performance is up a notch. Not a crazy noticeable difference from stock. But you can tell there is an improvement in gas mileage, the engine seems to run smoother when in the higher rpms, less work for the engine when going up a steep grade, there is audibly a more healthy purr... Overall pretty stoked on the mod. The main reason I got it was to help with my commute traveling up a long grade. When everything was stock, I would struggle, I felt like the slowest one on the HWY. With the header, I can maintain speed and the rpms hold better, I don't have to down shift nearly as much, It feels like the engine breaths better in those situations.