Cracked exhaust manifold

Lethldragon said:
How difficult is it to replace an exhaust manifold on a 97 jeep wrangler 4.0?
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buy one that has longtubes. any of the factory style replacements are just gonna crack again, even the ones with the "flextube" ends Ive replaced mine twice and welded it up last time. Its cracked again so Im savin my money til my v8 swap.... Its not hard to replace takes my about 2hrs to get mine off n back on...
 
I used a banks on mine. There are cheaper options but theirs is guaranteed for life. It can be a PIA to replace depending on the year though. Some are designed a little different due to getting by neighboring components. Still not that bad, just time consuming.
 
Cool, thanks, it's cracked between where the pipes come together and the flange, that ticking noise when you get on the throttle is bugging the he!! outta me
 
You have to take about everything off the drivers side of the engine. Start with the PS pump, then remove the wiring to the intake manifold stuff. Disconnecting the fuel injector connectors can be a little tricky. I broke one of the plastic vacuum pipe assemblies coming out of the valve cover, luckily I had a spare in my boxes of junk. Then you will use a good variety of extensions and wobbler sockets to get all 11 (I think) bolts that hold both the intake and exhaust manifolds on. Remove the intake, the exhaust will be held on with 2 more nuts, and if you havent disconnected it yet, 2 more nuts/bolts at the header exit.
Now is the best time to inspect and replace the drivers side motor mount.

Go thru a junkyard and check out all the 4.0L engines. You will see this is a very common problem.
 
oh yea be real careful when putting the intake back on and make sure the pins are lined up right if not you'll crack the intake whaen you tighten it down..... did this on my wifes cherokee....
 
X2 on removing the intake to get the exhaust off. Not necessarily hard, just time consuming. A new intake/exhaust gasket (they are one piece) is required (recommended?). I replaced my cracked OEM with a Borla off ebay for a good price, just takes some patience shopping around.... I wouldn't bother with an OEM, they all crack eventually. If your keeping the Jeep this is a worthwhile investment...
 
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