Exhaust popping issue - question before i re-install, new pics added of car Options

[william1764]

I removed the muffler to replace the gaskets in an effort to rid the popping on decel. Won't re-install until tomorrow because I decided to clean up muffler apply a coat of heat resist paint. Out of curiosity I started the car with just header/exchanger to see if popping still existing - it did. Does this mean my leak is before the muffler gasket (exhaust manifold gasket) or is this typical without muffler installed . BTW - there was clear evidence that the exhaust was escaping at least at one of the the muffler gaskets as you could see black residue on the bottom outside edge of the gasket (no seal).

[Bleyseng]

I'd pull the heat exchangers too and change the copper O ring gaskets. Before re-installing anything carefully flat file the gasket surfaces so they are flat and clean! On the Heat changers carefully maintain the same plane of the surface. Usually all these surfaces get distorted by torqueing on the bolts over and over again until they are not flat causing leaks.
To remove the Heat exchangers spray the nuts with PB Blaster one day, then again the next day and then carefully loosen em in a back and forth motion to not snap the exhaust studs. GO SLOW! Use lots of PB Blaster to keep the rusty suckers from binding and snapping the studs... (IMG:style_emoticons/default/chair.gif)
Then pull out the copper gaskets and install the new ones and don't over tighten the new copper nuts and snap a stud.
Use all new nuts and bolts on the muffler to Heat exchanger, I like to use Stainless ones...

[william1764]

I'd pull the heat exchangers too and change the copper O ring gaskets. Before re-installing anything carefully flat file the gasket surfaces so they are flat and clean! On the Heat changers carefully maintain the same plane of the surface. Usually all these surfaces get distorted by torqueing on the bolts over and over again until they are not flat causing leaks.
To remove the Heat exchangers spray the nuts with PB Blaster one day, then again the next day and then carefully loosen em in a back and forth motion to not snap the exhaust studs. GO SLOW! Use lots of PB Blaster to keep the rusty suckers from binding and snapping the studs... (IMG:style_emoticons/default/chair.gif)
Then pull out the copper gaskets and install the new ones and don't over tighten the new copper nuts and snap a stud.
Use all new nuts and bolts on the muffler to Heat exchanger, I like to use Stainless ones...

Easy peasy...yeah right (IMG:style_emoticons/default/blink.gif). I'll give it a go. Thanks for the directions (IMG:style_emoticons/default/beerchug.gif)