Hey, my 5.4L 06 F-250 4x4 has developed a exhaust leak over the last 6 months getting worse. I crawled under it & fired it up (remote start) & it sounds like it's coming from where the Passenger side header pipe goes into the exhaust pipe & it looks like where a Doughnut Gasket would be. BUT! Two parts houses & the local Ford Parts house says their computer doesn't offer a Doughnut Gasket. I tried to tighten & it's tight.
Has anyone had issues with this part/area? Or is the leak probably a exhaust manifold gasket?

Thanks,
Ronnie Knight

 

Usually a ticking sound in the exhaust is one cylinder leaking....I would look for a cracked manifold where it attaches to engine

 

The thing with a leaky, ticking exhaust is it is hard to pin point the exact spot were it is leaking without fiscally feeling the leak.

You still can ad a gasket to that flange joint. BUT you may need a torch to heat those flange nuts to loosen them.

Another common area that ticks in your exhaust system is at the exhaust manifold (Header). Sometime a manifold bolt will snap off at the front of the manifold or at the back of the manifold.