Well, I've been working on the old girl again, and this time (after replacing the idler pulley) I was able to hear an exhaust leak in the pickup. It sounds like its coming from where the manifold enters the exhaust tubing, so I was wondering if anyone had any quick fixes here? If not, what do you guys suggest for a new exhaust system?

 

First, make sure it's coming from where you think it is. Use a length of fuel or vacuum hose with one end held to your ear like a stethoscope to "sniff" around your exhaust manifolds and listen for the leak. Then, you can decide what to do about it.

 

One word of caution almost everyone that has tried to remove an exaust header has snapped off two studs very common.

A small leak may be best ignored if small

 

I though my exhaust was leaking at the exhaust flange, but I was wrong.
I just re-checked my exhaust this morning for leaks using the reverse port of a Shop Vac in the tail pipe. Worked great. I used a spray bottle and filled it with toy bubbles. I sprayed all around the exhaust manifold and found two large leaks on the passenger side and one small on the drivers side. Looks like I will be replacing my exhaust manifold gaskets soon and I hope this cures my rough idle that has stumped me for months.

 

You mean down at the exhaust flange? On my 98 the flange rusted and allowed the bolt head to pull out and left a 1/2in gap. I just got a new bolt and added a big washer so it wouldnt pull through the hole and it worked great. It was one of those quick fixes for the time being.

 

I mean I can definitely pick out the sound of the leak... even from inside the cab.

 

Yeah well your probally missing or have some broken exhaust manifold bolts for sure. look aound it is ussually the two rear most bolts on both banks. It will look like an empty hole. Not an easy fix if they are broken. I have seen at least 5 or 6 in the past few year all on the 4.7 including my own. Good luck and if you find an easy fix let us know. Mine actually gets quiet in about 5 mins.
Dave