A cheap fix to try, get a new gasket if yours is too bad to reuse. Apply a bead of high-temp exhaust silicone around each exhaust port on the gasket, both sides. Let it 'skin up' them install header. The silicone will help to fill any low spots in the flange. This has worked for me in the past. Also install with new locking nuts for the manifold studs, if they don't lock they will loosen up and you will have another leak.


'86 4Runner 5" SAS
'97 4Runner
'05 Corolla
'00 F250 PowerStroke