Installing new exhaust crossover gasket
Cruiser
Joined: Sep 2010
Posts: 160
Likes: 0
From: Virginia
Congrats!
Club Member
Joined: Feb 2007
Posts: 1,678
Likes: 3
Which way does the tapered end go into the crossover pipe? Does it go in toward the pipe or out towards the header pipe?
NM, I think I figured out that it goes down into the pipe...
NM, I think I figured out that it goes down into the pipe...
Last edited by TickTock; Dec 14, 2010 at 05:55 PM.
3rd Gear
Joined: Oct 2011
Posts: 7
Likes: 0
From: Wichita, KS
So, on my third trip back to the dealer for a gasket I stopped by Harbor Freight and picked up the medium tailpipe expander. Made the job a snap.
Thanks again. -Jay
Intermediate
Joined: Aug 2010
Posts: 39
Likes: 2
From: Mid-Atlantic
66813-09, that was the part # for crossover gasket on the '09 model. red.heritage, thank you for that advice, I to mangled a gasket on the first go around, never heard of the exhaust expander before. 
If I only knew yesterday what I know now I wouldn't be waiting 7 - 10 buisness days for dealer to get one in...
If I only knew yesterday what I know now I wouldn't be waiting 7 - 10 buisness days for dealer to get one in...
Elite HDF Member
Joined: Sep 2007
Posts: 4,928
Likes: 69
From: Near Myrtle Beach, SC
Yes, you will easily ***** this gasket up if you do not expand the mouth of the crossover pipe where the new gasket will reside.
You can use a section of pipe with an outside diameter of 1.75 inches..no bigger, no smaller. Cut it any length you want to work with. You then tap this pipe into the end of the crossover a little at a time. Of course the crossover needs to be in a vice or held very tightly while pounding in the pipe with a rubber hammer. Keep working it, taking your time. Do not get in a hurry. You are stretching metal and you need to take it nice and slow. Work the pipe into the mouth of the crossover far enough to where it will consume the gasket when you slip the gasket in the mouth of the crossover. You should be able to slide the gasket into the mouth of the crossover pipe without deforming the gasket and with very little pressure. If you are getting resistance, you have not adequately stretched the pipe. Keep at it.
As one post said above, the mouth of the crossover has already been compressed by the clamp, so that is why you must expand the mouth back to a pre-compressed diameter in order to get the gasket to seat in the mouth of the crossover. There are slits in this end of the crossover, so it's not that hard to get it expanded back to where it needs to be. That harbor freight expander might be a great tool for this, but I had this pipe of the correct diameter so I used it.
You can use a section of pipe with an outside diameter of 1.75 inches..no bigger, no smaller. Cut it any length you want to work with. You then tap this pipe into the end of the crossover a little at a time. Of course the crossover needs to be in a vice or held very tightly while pounding in the pipe with a rubber hammer. Keep working it, taking your time. Do not get in a hurry. You are stretching metal and you need to take it nice and slow. Work the pipe into the mouth of the crossover far enough to where it will consume the gasket when you slip the gasket in the mouth of the crossover. You should be able to slide the gasket into the mouth of the crossover pipe without deforming the gasket and with very little pressure. If you are getting resistance, you have not adequately stretched the pipe. Keep at it.
As one post said above, the mouth of the crossover has already been compressed by the clamp, so that is why you must expand the mouth back to a pre-compressed diameter in order to get the gasket to seat in the mouth of the crossover. There are slits in this end of the crossover, so it's not that hard to get it expanded back to where it needs to be. That harbor freight expander might be a great tool for this, but I had this pipe of the correct diameter so I used it.
Road Captain
Joined: Sep 2007
Posts: 742
Likes: 4
From: Twin Cities, MN
AWESOME advice!!
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Road Warrior
Joined: Feb 2010
Posts: 1,534
Likes: 10
Does anyone know if the tapered end goes into the crossover pipe, or onto the header pipe?
Thanks
