[Rick Nick]

Does anyone have a solution for flexible flange donut gaskets (no. 9 - front and no. 8 - rear, see first pic. below) that are leaking exhaust? My Catalytic Converter (stolen) and Rosonator were replaced with aftermarket Walker 16167 Converter and 56101 Resonator - see Walker pic. further below. I am getting fumes in cabin and check engine light is now on. Returned to Honda Dealership, who had put in the Walker parts, but they can't seem to solve this leaking exhaust problem; they attempted by replacing gasket and spring bolts with the same Walker parts. Anyone else have this problem with leaking flexible flange donut gaskets between Walker parts and Honda original muffler parts? Thank you, Rick.


HONDA ORIGINAL PARTs:

WALKER REPLACEMENT PARTS - 31531 donut gasket, front of converter, and 31360 donut gasket, rear of resonator, are both leaking badly - see soapy water leak test (I did) pics. below.

LEAKING DONUT GASKET 31531 between Walker converter and Honda manifold:

LEAKING DONUT GASKET 31360 between Walker resonator and Honda muffler:

 

[Rick Nick]

I think you should take it back to the dealer who installed the exhaust and have them figure it out. Part of the cost of hiring someone else to do it is them making sure it’s done properly.

If you’re looking to fix it yourself well … it’s obviously not sealing right so you’ll have to figure out why.

Yes, today I am taking it back again (twice now) to the Honda Dealership/Service Center. I posted this thread because it seems this particular Honda service center does not know how to fix the leaks and I was hoping someone had a similar leak experience and found a solution that I could relay to them.

Did you have new doughnuts fitted too? Aftermarket parts never fit as good OEM ones. In fact, I'm surprised that a dealer would even entertain fitting Aftermarket parts in the first place

Yes, they are installing aftermarket donut gasket parts. Honda OEM converter and resonator are not available (I checked on-line as well). Not sure about the gaskets.

 

[Rick Nick]

Did you have new doughnuts fitted too? Aftermarket parts never fit as good OEM ones. In fact, I'm surprised that a dealer would even entertain fitting Aftermarket parts in the first place

Yes, since the Honda dealership installed an aftermarket converter and resonator, they also installed aftermarket Walker donut gaskets - Walker 31531 (converter front flex flange) and 31360 (resonator back flex flange).

There are a huge amount of these Walker donut gaskets exists - https://www.walkerexhaust.com/content/dam/marketing/North-America/walker-exhaust/pdfs/Walker Gaskets and Flanges.pdf

I was thinking that maybe another donut gasket would solve the leaks and was hoping others knew which one.

And I just called Walker's support line (800-325-8886) and they had not heard of any leaking at those two Walker donuts gaskets: no solution from them. Guess my car is the only one that's leaking exhaust.

And Honda dealership still working on it; but still no solution there either.

And thank you Black Pearl UK and Everyone for your responses - for taking the time to give input!