The design of an exhaust manifold plays a key role in the performance of an engine because a back pressure is induced into the cylinders which lead to reduction in performance. The major design objective for any type of gasket is to possess compressibility, recovery and resistance to degradation subject to: flange, fluid to seal and atmospheric interaction. This paper describes the mechanics and failures of an exhaust gasket in an internal combustion engine. The mechanics of an exhaust manifold gasket is explicated by enlightening on compressive bolt, vibration and thermal loads; and failures are by thermo-mechanical influences, insufficient sealing and spot weld joint failure. A reliable approach is followed for developing the design considerations of an exhaust gasket by understanding the mechanics and overcoming the failures suffered. Hence, an adequate sealing stress and pressure distribution can be obtained ensuing to a mechanically efficient, low emission, highly durable and economic sealing joint.