I am very sorry there have been such problems with Doug Thorley Long Tube Headers and Doug Thorley Y pipe exhaust leaks. I feel we have a handle on this now.
The included Doug Thorley installation guide for the headers instructed the installer to reuse the stock gaskets and hardware. We knew that reusing a crush-to-seal gasket is never a good idea and we always recommended replacing the collector flange gaskets with new gaskets. They are available on our website so they can be ordered with the headers or the Y pipe.
We began getting a lot of complaints from our customers that installed the Doug Thorley Y pipe along with the long tube headers. The number of complaints concerned us. On my last trip out to California I looked into this problem to find the cause and solution to the problem.
So, I contacted Doug Thorley and asked if I could bring two of these leaky trucks to their facility for inspection. One truck was the well known FJ Cruiser owned by Air2Air and the other was the first customer to receive the Tacoma version of the Doug Thorley “Pipe Bomb.”
Once these systems were disassembled it was readily apparent what was causing the gasket failures. The recesses on the flanges for the gaskets had a much large diameter than the stock gaskets. Because of this the gaskets would not stay centered in the flange during assembly and could slide slightly out of position causing a leak.
The guys at Thorley & I agreed that an easy fix for the DT Y-pipe would be a gasket with the same inner diameter, but a larger outer diameter would be needed to keep the gasket centered in the flange recess during assembly.
Reusing the stock gaskets as suggested in the installation instructions is not going to work.
The larger gasket was installed in both of these trucks and the leaks disappeared. As far as I know the new gaskets are still working perfectly as we expected.
URD now has these larger gaskets in stock and they are available to anyone that needs them.
If you have the URD Y-Pipe the stock gaskets will still work fine. Our flange design on the URD Y Pipe has a centering tit that holds the gasket in place during assembly so it cannot slide out of position. If you have the URD Y pipe and stock manifolds we recommend the stock gasket. If you have the URD Y Pipe and the Doug Thorley Long Tube headers, the stock gasket will work, but it would better to use the new larger one. If you have the Doug Thorley Y Pipe and the Long Tube headers, you must use the larger diameter gasket.
Any customers that have purchased the Doug Thorley Long Tube Headers or the Doug Thorley Y pipe from URD (that have leaks), please contact URD for a free set of the correct gaskets (support@URDUSA.com). If you purchased the headers from Thorley or another vendor, URD has these on its website.
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