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Old 08-12-2013, 07:41 AM   #1
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Exhaust Manifold CRACK!!!!

I know the Manifolds are prone to cracking, Have a 98 TJ 2.5, is there a fix to this or just something we live with?

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Old 08-12-2013, 07:44 AM   #2
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Depends how,bad it can cause major damage. I bought a after market one from a salvage yard(new part) and it was 100..00 the newer ones have flex and not rigid. Cost me 400 for install

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Old 08-12-2013, 07:45 AM   #3
Knows a couple things...

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It's not something you can just live with and it can't be repaired. The only fix is to replace it with a replacement header like you can get from Amazon.com or eBay.

Look for a replacement like this one that has flexible steel expansion joints like the below replacement header... they allow it to flex instead of crack. And no, the cracks can't be welded since the header will just crack again right next to the welds. Engine torque flexes the header which causes the cracking.
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Old 08-12-2013, 08:00 AM   #4
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Hey Jerry, Do the 4banger manifolds have the flex joints in them as well do you know?
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Old 08-12-2013, 08:04 AM   #5
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I've replaced mine on 1998 TJ 4.0, but think I remember that the 2.5 was a recall item? Maybe I'm losing it... Worth a call to Dealership maybe? Good luck!

Edit: can't find that recall after searching...sorry
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Old 08-12-2013, 08:11 AM   #6
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Yeah, not sure they will cover it beings, I replaced it with an aftermarket one about 2 years ago. worth a shot though. Thanks
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Old 08-12-2013, 11:41 AM   #7
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Quote:
Originally Posted by TJTim316 View Post
Hey Jerry, Do the 4banger manifolds have the flex joints in them as well do you know?
All the older TJ's are ridged
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Old 08-12-2013, 08:22 PM   #8
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I have a 98 4.0l with cracked exhaust manifold and took it to the local exhaust shop. He does jeeps the majority of the time so knows where they crack. He welded inside and out on all the spots it has cracked or would crack and has never had one been brought back. Costed a tad over 200 and havent had a problem in a few months now.. Just another opinion. If it cracks again ill just buy the new one with flex joints but for now mines great and saved me some money
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Old 08-12-2013, 08:40 PM   #9
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I've had a hell of a few months with manifolds...
I replaced my original, lasted 240k
In the last 5k I've had 3 dorman manifolds, I replaced the motor mounts this time as the originals were worn. I hope this is the last time I have to replace it...
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Old 08-12-2013, 10:16 PM   #10
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Quote:
Originally Posted by thgr8alex View Post
I have a 98 4.0l with cracked exhaust manifold and took it to the local exhaust shop. He does jeeps the majority of the time so knows where they crack. He welded inside and out on all the spots it has cracked or would crack and has never had one been brought back. Costed a tad over 200 and havent had a problem in a few months now.. Just another opinion. If it cracks again ill just buy the new one with flex joints but for now mines great and saved me some money
See mine was too far gone i guess
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Old 08-12-2013, 10:19 PM   #11
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Quote:
Originally Posted by Jerry Bransford View Post
It's not something you can just live with and it can't be repaired. The only fix is to replace it with a replacement header like you can get from Amazon.com or eBay.

Look for a replacement like this one that has flexible steel expansion joints like the below replacement header... they allow it to flex instead of crack. And no, the cracks can't be welded since the header will just crack again right next to the welds. Engine torque flexes the header which causes the cracking.
Check the down pipe bolts before you install. The nuts weren't cut right and wouldn't go all the way down. Had to replace them with some replacements from Ace.
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Old 08-13-2013, 12:18 AM   #12
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if you do it yourself, can cut down alot of time leaving injectors in intake manifold removing throttle cable and other connections routing on top of it, 95 dollar ebay flex, 120 dollar headpipe and cat, 30 dollar walker muffler from autozone.... so for under 300 can redo your whole exhaust.. wanna probably by some new bolts from the stealership cause some of mine were very compromised... did it in a very reasonable amount of time... maybe 6-8hrs, thats what i did.. just throwing out ideas to people' I repaired headpipe gromit got the dreaded death wobble due to a stripped out front adjustable trackbar, my cat and and manifold cracked... so this was my best route
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Old 08-13-2013, 07:02 AM   #13
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Everyone keeps telling him to get a manifold with the flex pipe. OP has a 2.5 not a 4.0....

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