2020 Corvette Header Problems: Diagnosing and Repairing Exhaust Issues

How to Address Header Concerns

Experiencing header issues with your 2020 Chevrolet Corvette can be frustrating. Many owners modifying their vehicles encounter similar challenges. As one owner shared, "Personally, I think you should do it all at once and avoid the tune fee repetition cost. You might want to check with Tony, tell him your plan and see if he'll work with you if you throw a set of heads/headers on later." This guide will help you understand and address common problems related to headers in your vehicle.

Symptoms

Owners have reported various symptoms that could indicate header-related issues. One common concern is unusual noises. For example, some describe an "ear piercing" sound, suggesting a possible exhaust leak or improper installation. This can be particularly noticeable during cold starts when the engine is working harder.

Another symptom mentioned is "gear whine." While not directly related to the headers themselves, modifications to the exhaust system, including headers, can sometimes amplify or alter the perceived sounds from the transmission. This might be due to changes in exhaust resonance and the way sound waves travel through the vehicle.

"Pulling" is another symptom mentioned, though it's less directly linked to the headers. This could indicate other issues with the car's alignment or suspension but might become more noticeable after modifying the exhaust system. It's essential to rule out other potential causes before focusing solely on the headers.

Finally, "noise" in general is a common complaint. This can range from exhaust leaks to rattling or vibration caused by improper header installation or contact with other components. Identifying the specific type of noise is crucial for pinpointing the exact issue.

Most Likely Cause

Based on owner reports, the most likely cause of header-related issues in your vehicle often stems from modifications done in conjunction with a six-speed transmission or during related exhaust system upgrades. When installing headers, it's crucial to ensure proper fitment and sealing to prevent leaks.

Modifying the exhaust system can also affect the overall performance and sound characteristics of the car, potentially amplifying existing noises or creating new ones. For instance, installing a "billy boat bullet axle back" or aftermarket "mufflers" can change the exhaust note, sometimes revealing underlying issues.

Remember, any changes to the exhaust system can also impact other components, such as the air system. Ensure that all related systems are functioning correctly after any modifications. As MWWarlord noted, "It typically only goes over 200 on a hot day when I was driving fast, and then end up in stop and go traffic Unfortunately, due to various (non-car related) issues, I still have not done the headers yet."

How to Diagnose

Diagnosing header issues requires a systematic approach. Start by visually inspecting the headers for any signs of leaks, cracks, or loose connections. Look for soot or discoloration around the header flanges, which can indicate exhaust leaks.

1. Visual Inspection: Check the headers for visible damage, such as cracks or dents. Examine the flanges where the headers connect to the engine and the exhaust system. Look for any signs of exhaust leaks, such as soot or discoloration.

2. Listen for Leaks: Start the engine and listen carefully for exhaust leaks, especially around the header flanges and connections. You can use a stethoscope or a piece of hose to help pinpoint the location of the leak.

3. Smoke Test: A smoke test can help identify even small exhaust leaks. Introduce smoke into the exhaust system and look for smoke escaping from any potential leak points.

4. Check Connections: Ensure that all bolts and fasteners are properly tightened. Loose connections can cause exhaust leaks and other issues.

5. Inspect Gaskets: If you suspect a leak at the header flanges, inspect the gaskets for damage or wear. Replace any damaged gaskets.

Tools needed for diagnosis include:

• Mechanic's stethoscope
• Smoke machine (optional)
• Wrenches and sockets
• Flashlight

Step-by-Step Fix

Here's a step-by-step guide based on owner experiences on how to address header issues:

1. Gather Necessary Tools and Parts: Ensure you have all the required tools, including wrenches, sockets, jack stands, and potentially a car lift. You'll also need new gaskets, bolts, and any other necessary replacement parts. As Dins74 noted, "Mobile Hydraulic Car Lifts Well guys after decades of sliding my now old a@# under my C3 on cold garage floors with the car on jack stands that yes always seem to be in the way, I started researching the Mobile Lift Market."

2. Prepare the Vehicle: Safely lift the vehicle using a jack and secure it with jack stands. Allow the engine to cool completely before beginning work.

3. Remove Existing Headers: Carefully disconnect the exhaust system from the headers. Remove the bolts securing the headers to the engine. Be prepared for tight spaces and potentially corroded bolts.

4. Inspect Header Flanges: Inspect the header flanges for any signs of damage or warping. If the flanges are damaged, you may need to replace the headers.

5. Install New Gaskets: Install new gaskets between the headers and the engine. Ensure the gaskets are properly aligned and seated.

6. Install Headers: Carefully install the headers, ensuring they are properly aligned with the engine. Tighten the bolts to the manufacturer's specified torque.

7. Reconnect Exhaust System: Reconnect the exhaust system to the headers. Ensure all connections are secure and properly sealed.

8. Test for Leaks: Start the engine and listen carefully for exhaust leaks. Use a stethoscope or smoke test to identify any leaks.

9. Adjust as Needed: If you find any leaks, tighten the connections or replace the gaskets as needed.

10. Lower Vehicle: Once you are satisfied that the headers are properly installed and there are no leaks, carefully lower the vehicle.

As one owner shared: "It definitely looks like a pita. Family and work put my schedule off today in different spots, but I'm finally sitting down to pull the diff/trans and swap it." (source). This highlights that the task can be challenging, so patience and attention to detail are key.

Parts and Tools Needed

• Header gaskets (specific to your 2020 Chevrolet Corvette engine)
• Header bolts (if replacing)
• Wrenches and sockets (metric)
• Torque wrench
• Jack and jack stands (or a car lift)
• Penetrating oil (for corroded bolts)
• Mechanic's stethoscope
• Smoke machine (optional)

Real Owner Costs

The cost of addressing header issues can vary widely depending on whether you choose to DIY or hire a professional.

DIY:

• Header gaskets: $20 - $50
• Header bolts: $10 - $30
• Tools (if needed): $50 - $200
• Total estimated DIY cost: $80 - $280

Professional Installation:

• Labor: $300 - $800 (depending on the shop and complexity of the job)
• Parts: $20 - $50 (gaskets) + potential cost of new headers if required.
• Total estimated professional cost: $320 - $850+

Some owners have opted to combine header installation with other modifications, which can affect the overall cost. Keep in mind that some issues may require professional expertise.

Prevention

To prevent future header issues, follow these tips:

• Proper Installation: Ensure that headers are installed correctly, with properly torqued bolts and new gaskets.
• Regular Inspections: Regularly inspect the headers for any signs of leaks or damage.
• Use Quality Parts: Use high-quality gaskets and bolts when replacing parts.
• Avoid Over-Tightening: Over-tightening bolts can damage the header flanges and cause leaks.
• Professional Assistance: If you are not comfortable working on your car, seek professional assistance. As vette4fl shared, "I feel like I was chasing my tail with setup last year and I finally have the car doing what I want. This being my local track I was pumped to really see what it would do." (source), indicating proper setup is vital for performance and minimizing issues.

What Owners Say

Real experiences from CHEVROLET owners:

Owner Experiences

"Quote: Originally Posted by Prop Joe I just looked and they are out of stock on the Brawlers. Take Smitty's injectors (if he finds them), you'll need them at some point." — Midwayman (source)

"Family and work put my schedule off today in different spots, but I'm finally sitting down to pull the diff/trans and swap it. Got my coffee and music on deck." — Tusc (source)

"It definitely looks like a pita. Family and work put my schedule off today in different spots, but I'm finally sitting down to pull the diff/trans and swap it." — Tusc (source)

Lessons Learned

⚠️ "My coolant temps are generally between 195-205. It typically only goes over 200 on a hot day when I was driving fast, and then end up in stop and go traffic Unfortunately, due to various (non-car related) issues, I still have not done the headers yet." — MWWarlord (source)

⚠️ "It typically only goes over 200 on a hot day when I was driving fast, and then end up in stop and go traffic Unfortunately, due to various (non-car related) issues, I still have not done the headers yet." — MWWarlord (source)

Pro Tips from Owners

💡 "Personally, I think you should do it all at once and avoid the tune fee repetition cost. You might want to check with Tony, tell him your plan and see if he'll work with you if you throw a set of heads/headers on later." — Midwayman (source)

FAQ

Q: How long does it take to fix header issues?

A: The repair time can vary depending on the complexity of the job. Replacing gaskets can take 2-4 hours, while installing new headers can take 4-8 hours.

Q: Can I drive with exhaust leaks?

A: Driving with exhaust leaks is not recommended as it can be dangerous. Exhaust fumes can enter the cabin and cause health problems. Additionally, exhaust leaks can damage other components and reduce fuel efficiency.

Q: Is this a common issue on the 2020 Chevrolet Corvette?

A: While not all vehicles experience header issues, it can be more common on cars that have been modified or driven aggressively.

Q: DIY vs mechanic - what's recommended?

A: If you have experience working on cars and are comfortable with the tools and procedures, DIY is a viable option. However, if you are not confident or lack the necessary tools, it's best to seek professional assistance from a qualified mechanic. The six speed can make this a difficult job. "Quote: Originally Posted by Prop Joe I just looked and they are out of stock on the Brawlers. Take Smitty's injectors (if he finds them), you'll need them at some point." As Midwayman shared, additional considerations might arise during the process.