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Old 05-25-2009, 06:09 PM   #1
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Broken exhaust manifold in head...

Well,my "new" '97 2.5L TJ had (has) a huge exhaust leak when I bought it. The flange at the head pipe was VERY loose, so I figured that had to be the culprit and would be an easy fix. After cleaning and reassembling that nice and tight with some Ultra Copper, I still have the same leak! Sounds like CRAP! So, I look further and the manifold is missing the rearmost bolt. Tried to stick a small allen wrench in there and it only goes in about 3/4 inch, or maybe .100" below the level of the head. This tells me the bolt is busted off in the head.

Anybody ever dealt with this issue? Looks like *maybe* if I get a right angle drill I can get in there and try to drill it out.

Also, there appears to be no gasket on the exhaust (the intake gasket loops over the exhaust ports). Is this correct? I thought from the factory they had a gasket?

Any thoughts would be appreciated. Even if I have to take it somewhere (which will cost a LOT, I'm sure) I can't live with this noisy beast!

Thanks, Jay

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Old 05-25-2009, 07:48 PM   #2
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i would try drilling a small hole in the middle of the stud and use an ez-out to extract it. with the head broken off there is no torque on it so it should spin out fairly easily.

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Old 05-25-2009, 09:03 PM   #3
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ya, they usually come out without too much hassle, and the intake gasket is also the exhaust manifold gasket, one gasket does both.

you might just wanna take the manifolds off, extract and replace the bolt, and replace the gasket.
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Old 05-25-2009, 09:37 PM   #4
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Yeah, the only way to have any room will be to take out the intake and exhaust, but still don't know if it'll be enough. Thanks for the replies.
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Old 05-25-2009, 09:37 PM   #5
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once those manifolds are off, the head comes off in about 10 mins.
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Old 05-25-2009, 09:43 PM   #6
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Go to home depot or blowes and get the flex line that you can put bites and nut drivers etc in. The line it a flexable but rigid enough to hold its postion so you can bend it to get the line in there but still be able to drill it out.
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Old 05-26-2009, 09:10 PM   #7
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Thanks for the info guys! We'll see... still debating if I just want to take it to a shop.
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Old 05-26-2009, 09:21 PM   #8
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I had that exact problem with mine and was a total pain in the ass. I was using good drill bits and a right angle drill and still had the bit walk a little and in the end the stud was still holding tight. took a long time to get it done and i still fudged it a little thinking ill fix it right or get a new head when my headgasket needs replacing. If i had to do it again i would remove the head all together and work comfortably on my work bench and then replace all gaskets etc...

btw, mine didnt have exhaust gaskets either. strangebut installed without gaskets and no leaks.
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Old 05-27-2009, 10:28 AM   #9
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exact problem my 97 tj 2.5l had when i got it...
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Old 05-27-2009, 05:03 PM   #10
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Well, just dropped it off at a shop. Will let you know what the $$$ ends up being for future reference!
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Old 05-27-2009, 06:03 PM   #11
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Here ya go

Im working on the same deal..kinda, im replacing my header and the only way to get the manifold off is to remove all eight screws from the manifold the 4 underneath are a little bit of a pain but if u get a expansion for your socket wrench you should be golden. And if you go to lowes or homo depot they have a new drill out thats small but packs a big punch so you can fit it in almost any area. If you have any other question send me a private message i still have my manifold out and header so if you need pics or somethin be glad to help out. I know how stressful it gets when you cant get S%!t done cause of a simple issue
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Old 05-28-2009, 06:09 PM   #12
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Well, here we go... shop called today and had it tore down. Not only did it have the bolt broke off but it had a crack down the middle of the exhaust manifold! He said he found used and new locally and both were about the same price (?). I thought about getting a header, but figured it'd be about as much and take a few days to get here so told them to go for it. Total bill will be $600, and I was hoping for about half that. Guess I'll be spending what I had hoped to be "35 inch tire money" on getting a quiet Jeep!
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Old 05-28-2009, 06:24 PM   #13
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Is this your daily driver? If not, i would have torn it down myself. You would be very surprised on just how easy these motors are to work on. You have lots of room, and can see what you are doing.
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Old 05-28-2009, 06:36 PM   #14
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Old 05-28-2009, 07:58 PM   #15
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Do it urself its not hard! takes a couple hours a day if thats all you have

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