I have a 1999 Tahoe and have done some upgrading to the engine. I recently added headers but have run into the problem of the passenger collector gasket blowing out. I have tried several types of headers but it results in the same thing. If anyone might know how to fix the problem it would be greatly appreciated.

 

The gasket can fail if the surfaces are not flat. Check the header flange and the exhaust pipe flange. Make sure they line up.

Use a straight edge to check for gaps. If there is a gap, fix the surface or replace the part.

Make sure the bolts are tight. Tighten them in a pattern and check them again after running the engine.

Use new bolts and lock washers or thread locker so they do not come loose.

Check engine mounts. If the engine moves, it can put stress on the joint.

Make sure the exhaust system is supported. Add a hanger if needed so the weight is not on the header.

You can also try a metal gasket instead of a fiber one.