when i installed my x pipe there was some plastic sleeve on the passenger manifold studs that i had to have someone take off with a torch. it wouldnt allow the midpipe to tighten down all the way on the passenger side giving me an exhaust leak/tick
check to see if yours is like that
not really sure. mine was fine at first but after a week driving it the leak developed. a week < year so i am not really sure.
if you have a camcorder take a vid, pload it to photobucket.com and share it so we can hear t first hand
I once went to a ford stealership to buy some. They told me they didnt have any, but gave me the nut size and everything. Went to the hardware store and brought some which was noticeably smaller but the same size from the paper.
Installed 2 on the passenger side and the leak got worse lol. Just order them from FORD even if they have to order it a state away from another dealer.
if you dont smell exhaust then its not a leak (at least the midpipe/manifold connection)
should have mentioned this before. your cabin would wreak of exhaust if you had a leak here
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