How To Fix An Exhaust Leak Without Welding?

Well, the general way of fixing the exhaust leak is to have it welded.  But do you know that you can fix an exhaust leak of your vehicle without welding too?

However, fixing the exhaust leak without power tools or welding can be challenging if you are not well-aware of the method.

Today, I will reveal how to fix an exhaust leak without welding with simple and easy methods in this article. Therefore, if you are new or not well trained, just follow each instruction thoroughly.

How To Fix Exhaust Leaking Without Welding?

Mostly, the leak from the exhaust tubes produces weak fuel economy and maintenance costs. But the good news is you can fix that issue without even using any welding process. Such as Fixing the Leak with Epoxy or, with Patch and you can even Repair Tape for Exhaust.

Before moving to the main method let’s have a glance at the required tools for the job-

Sealing The Exhaust Leak Repairing The Exhaust Pipe  Repairing The Exhaust Manifold Gasket
Wheel Ramps Gloves, Safety Glasses Rachet
Epoxy Glue Flashlight Sockets
Screwdriver Floor Jack, Safety Jack Stand Wench
The Patch Of Tin Can Wire Brush Hammer
Exhaust Leak Repair Tape Screwdriver Penetrating Oil
Sandpaper Stainless Steel Hose Clamps Gloves, Eye Protective Glasses
Clamps Or Clips Soda Can, Steel Wool
Muffler Repair Tape
Tin Snips

How Do You Seal An Exhaust Leak Without Welding?

Let’s learn how you can do that more easily-

Scrubbing The Entire Leaked Area:

Since most vehicles suffer from the leak on the underside, often that area gets packed with mud, rust, or dirt. First, locate the leaking area and scrub that surrounding area with a steel-toothed brush. Remember that most repairing or fixing work will not work, if you do it on a dirty or grime surface. So, you should Scrub the pipe entirely around the leak, including the top side too.

Preparing The Surface Of The Pipe:

Now take fine-grit sandpaper and use it to clean the repairing part of the pipe. Scrubbing the repairing portion of the pipe creates tiny micro-abrasions in the metal. Which also helps the tape or epoxy adhering. So, make sure-

  • you are scrubbing the entire repairing surface of the pipe thoroughly.
  • To create a stronger bond of a patch, rough up the metal surface properly.

Wiping The Surface:

Next, to clean the leaked surface thoroughly, wipe it down with acetone. It will also help the exhaust epoxy to bond with the metal. But be aware of protecting your face, eyes from acetone’s drips.

Since acetone is the primary component of making nail polish removers, you can also use a nail polish remover instead of acetone.

Determining The Hole Size:

It’s time to determine whether your hole size is small enough to seal without a patch or not. Note that for simple pinholes or, cracks you can use epoxy or tape for sealing. But for large holes, you will surely need a patch.

An attempt to seal the larger holes without a patch can result in an imperfect seal, and your exhaust leak may also resurface after the new hours of driving.

Wrapping The Exhaust Tape:

Next, wrap the exhaust tape all around the pipe, and put two layers of that tape to cover the leaking area securely. Remember different types of repairing tapes require separate applying methods, so make sure you have read the given instructions-

  • Some repairing tapes require your pipe to warm up before applying. That means you have to start the vehicle’s engine and run it for few minutes beforehand.
  • Some types require to be wet before you put it on the leaking area.

Mixing The Epoxy And Apply On:

Use a wooden dowel to mix the two parts of the epoxy to seal your exhaust leak. When your mixing is done, instantly apply it by dabbing over the leak. Also, use the wooden dowel to spread the epoxy around the entire area.

  • Make sure you are leaving a thick layer of epoxy there.
  • If you want, you can also apply the exhaust repair tape over the thick layer of epoxy.
  • Make sure you have read the instruction given on the epoxy package beforehand since the curing rates may vary for different types of epoxy.

How Do You Seal An Exhaust Manifold Leak?

If you wish to repair exhaust leak without welding for your manifold, then just follow the below instructions thoroughly-

Inspect And Check The issue:

When you are suspecting of a faulty exhaust manifold gasket, you should pop the hood of your car to inspect. If you notice an oily liquid covering your engine, then a gasket leak is most likely the problem.

Disconnect The Wire And Wait Till The Engine Cool Off:

After you have identified the exhaust manifold leaking issue correctly, disconnect the negative wire of your vehicle’s engine battery. Then, wait till the engine cools off.

Disconnecting The Covering Parts:

Now, put your vehicle’s parking brake on and raise the positioning of your vehicle with a jack stand. The manifold gaskets are securely bolted to the engine’s cylinder head. So, you have to use the tools to disconnect all parts to have a clear look.

Spraying Penetrating Oil:

Now spray penetrating oil on the gasket and the bolts that connect the manifold to the exhaust pipe flange. After you finish the spraying, let the oil sit for some time before moving to the next step.

Removing The Bolts With A Wrench:

After the parts have soaked completely, use a wrench to loosen the exhaust manifold bolts. Also, be careful not to put too much pressure. The bolts are supposed to come off easily in that way. But if you still struggle, you can use a hammer to speed up the process.

How To Fix An Exhaust Leak On Flange?

You can easily fix the issue just by following the below instructions-

  • First, you need to turn off the vehicle and wait till it cools off.
  • Now wear your gloves and protective glasses and clean the leaking area with a steel brush.
  • After that, use sandpaper to rough up the pipe’s area where you needed the repairing work done.
  • Now clear that damaged area with acetone. If the size of the hole is smaller, then use an exhaust tape of epoxy.
  • If the hole is larger then use a clamp to fix the issue.

How To Fix Exhaust Pipe Without Welding?

If you wish to fix your exhaust pipe without welding, you can follow below mentioned temporary method-

  • First, use a jack stand to lift your vehicle and let your vehicle cool off.
  • Then, measure the crack size, then based on that measurement, bring a portion of a tine of steel sheet.
  • Next, make two clumps and wrap that soft metal around the damage.
  • Now tie both ends with a firm grip.


Can You Use Foil Tape On Exhaust Or Gorilla Tape To Fix Exhaust?

You can use foil tape, but I recommend wrapping a few layers around the repairing surface. Then, tightly wrap the wire around that to hold it in the right place. Gorilla tapes are great, but the tackiness of them can loosen from the heat.

Can You Use JB Weld To Fix An Exhaust Leak? 

You can use JB weld for repairing the hole in your exhaust or muffler.

Can You Fix An Exhaust Leak With Duct Tape?  

No, you should not use it. Duct Tapes are not good for fixing the exhaust leak.

How long Does An Exhaust Sealant Putty Take To Dry?

It takes mostly 24 hours to dry off properly.

Final Words

To make your task less stressful, I have explained each and every detailed way of how to fix an exhaust leak without welding to guide you in the right direction.