I've had my '96 Formula for almost 20 years. This will make the third time it's developed the intake oil leak.

Have there been any new developments in the way of gaskets, seals, etc. that can help stop this problem? Or, is it still the same old fix?

 

My original never leaked, but neither has it the two times I have had mine off using Ultra Copper to seal the ends. I dimpled the end surfaces.

 

Guess I'll try Ultra Copper.

 

Ditto... original never leaked, stroker build never leaked. Ultra copper.

Shoebox has some recommendations in his cam install procedure:

4th Gen LT1 F-body Cam Install

Use dowels in the bolt holes on one side to slide the manifold straight down on the heads.

Allow the RTV to cure for 24 hours before starting the engine.

Torque the manifold bolts in two stages, and check them after driving it for a while.

 

Same here...Ultra copper to repair a leaky manifold and then when I did the heads/cam work. The absolute key is to make sure the surfaces are clean and then let the sealant cure for 24 hours...just like the instructions say. People just have to resist the urge to start the car right after assembly! Remember that it's a chemical seal, not a mechanical one and it needs time to work...

 

Mopar...

solid 411 already noted in this thread.

For chronic sealing issues (assuming the install process is done correctly) dimpling the rear of the block and intake with a punch or carefully with a drill is a reported solution Shoebox refers to.

Many report the Permatex Ultra Copper RTV is the best for this job. I have never used it but many do. I have used Permatex Black Ultra without issue several times (engine service/builds, not leaking manifold). I also wipe mating surfaces with a clean rag and acetone and use the FelPro "printo" seal intake gaskets (although they have nothing to do with rear intake leak). Any RTV needs to cure overnight before use or it will likely fail and leak

 

14 years 100k+ miles since the last time intake was off, I used Permatex "the right stuff"

No leak.

I followed above 1) thoroughly clean 2) pin punched dimples in block 3) let it sit for 24 hours