Found my exhaust leak.
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Cadillac CTS First Generation Forum - 2003 - 2007 Discussion, Found my exhaust leak. in Cadillac CTS Coupe, Sport Sedan and Sport Wagon Forums; Car developed a bad exhaust leak today about half way to work. After a brief search I found something interesting. ...
  1. #1
    Planktron's Avatar
    Planktron is offline Cadillac Owners Fanatic
    Automobile(s): 03 CTS 5M Luxury/Sport: V rear bumper and V exhaust
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    Found my exhaust leak.

    Car developed a bad exhaust leak today about half way to work. After a brief search I found something interesting. I hope the threads aren't gone from the pipe, but logic insists they probably are.

    OK won't let me post pics. Found the upstream driver side O2 sensor dangling by its pigtail. Threads on the sensor look rough, but they don't look too bad in the pipe. Fingers crossed for a cheap repair...

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  3. #2
    Planktron's Avatar
    Planktron is offline Cadillac Owners Fanatic
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    Thread Starter
    So apparently the hardest thing in the world to find is an M18 tap/die. Anyone know what pitch these are?

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    Planktron's Avatar
    Planktron is offline Cadillac Owners Fanatic
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    Threads in the manifold are beyond repair. This gets yuckier every day.

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    Calgary03 is offline Cadillac Owners Member
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    Try a helicoil. Not sure if that's the right spelling. Used them on industrial machines before and they worked great. Worth a shot
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    Fill in the f'ed holes with weld. Drill out and tape again.

  7. #6
    Planktron's Avatar
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    I was thinking of grinding the existing bung down then welding a new one on. The passenger exhaust manifold looks like a beast to remove and snapping a stud is always a possibility. Fingers crossed...

    A used manifold is $75 at the local yard, so that's an option too. More expensive but no welding and more peace of mind.


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    Planktron's Avatar
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    Bump. I'm still fighting this. I have a new sensor and also a used manifold at my disposal. I'm currently working 6 Days, and the passenger manifold doesn't look like a one day job. I'm thinking if I can take it somewhere and have them remove the exhaust system, they might have enough room to weld a bung on, but a buddy at work says welding cast iron is not easy as it likes to crack. Thoughts?

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  9. #8
    CTSM is offline Cadillac Owners Enthusiast
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    Re: Found my exhaust leak.

    Check this out: http://www.aemelectronics.com/no-wel...-2-5-inch-1174

    You can fill the old hole with weld completely, then drill the hole somewhere else then use that AEM product or similar product, clamp it and if it works, weld it too for extra security.

    Or of course if its doable eliminate the original bung as you mentioned and use this clamp on bung in the hole of the original one.
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  10. #9
    Planktron's Avatar
    Planktron is offline Cadillac Owners Fanatic
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    Nice! Thanks.

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  11. #10
    holsgo is offline Cadillac Owners Fanatic
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    Re: Found my exhaust leak.

    That AEM product is pure genius. PS, you can braze the bung closed. Brass would be fine except if you redlined the engine and the exhaust heated up red hot. I doubt that would happen constantly enough to destroy the braze. Just an fyi if you only have oxy/acetyl.
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  12. #11
    CTSM is offline Cadillac Owners Enthusiast
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    Re: Found my exhaust leak.

    With all that heat and vibration in addition to the heat cycles, I would be more worried about cracking of the melted metal rather than metling, certain brazing rods of silver base have a higher remelting point and would work when it comes to handling the temps but cracking resistance is another story and would put the OP back at square one. I think if possible he should definitely cut and grind down the original bung and clamp the clamp on bung in the hole of the original that would work out best IMHO.
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