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Old 04-17-2011, 10:39 AM   #1
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Exhaust manifold leak - TJ 2.5

I have an exhaust leak that's pretty loud until it heats up good and then it gets a bit better. I've been searching through the forums for info about this but all I really keep finding is info on the (apparently very common) 4.0 manifold issue. Before I run out and buy a new manifold, I thought I should check with you guys to see if the 2.5s have any known habits of cracking/warping too. Wasn't sure if I'm gonna end up with a bad manifold or just a bad gasket or seal. I'm having trouble determining exactly where the leak is located.

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Old 04-17-2011, 10:43 AM   #2
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i brought mine into a muffler/brake shop and they welded up the cracks for me, free, mine is a 4.0 though so not sure if the 2.5s have the same problems

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Old 04-17-2011, 05:02 PM   #3
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Yeah my 2.5 was cracked on both sides. Sounded a lot like a log truck when it got that bad.
If you decide to change it yourself, instead of labeling every vacuum line, and everything else just take a few pics of where the lines go on the intake. It saved me about an hour just doing that. I attempted to do things by the Chilton Manual I had but I tossed it within 30 minutes into it. it took about 3 hours to do mine. It took us 5 hours on a friends cause he had a broken stud.
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Old 04-17-2011, 05:06 PM   #4
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addition: If you spray every bolt and nut with PB Blaster once a day, everyday for 3 days prior to replacing the manifold it makes them easier to be removed.
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Old 04-17-2011, 05:25 PM   #5
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Quote:
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addition: If you spray every bolt and nut with PB Blaster once a day, everyday for 3 days prior to replacing the manifold it makes them easier to be removed.
Thanks for the tip!! Very good info!! What are the chances that I have a bad gasket or seal opposed to having a bad manifold?
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Old 04-17-2011, 06:09 PM   #6
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My 2.5 didn't have an exhaust manifold gasket on it. It came from the factory metal on metal. The only gasket I had to take off was the one for the intake. I did put a gasket that covered the intake and exhaust manifolds on it when I installed a new one though.
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Old 04-18-2011, 09:34 AM   #7
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I had same problem and bought new manifold only to find out studs were broken off.
If yours is indeed manifold i have the used one that was good. Give u a good deal on it. But I would check the studs first common problems i guess.
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Old 10-19-2011, 05:11 AM   #8
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My 2.5 didn't have an exhaust manifold gasket on it. It came from the factory metal on metal.
So did mine (EFI), no gasket. Weird.
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Old 10-19-2011, 06:43 AM   #9
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Mine sounded bad, it was missing 2 bolts and no gasket. Got new exhaust and intake gasket and put new bolts in, quite as a mouse now.

Put you some flour, baking soda, something powdery on the manifold and turn the jeep over. If it has a crack on the top side it should blow the powder away from the spot.
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Old 10-28-2011, 11:09 PM   #10
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I have actually had this problem now twice. The first time I had a cylinder head machine shop repair the manifold using a process that includes drilling holes in the crack and putting a break away bolt in it then weld the bolts together. It worked for about three years and I am now in search of a replacement manifold. Mine is cracked on the side nearest to the block. It isn't uncommon because the pipe hangs on the manifold and you have temp fluctuations that stress the cast iron. Omix-ada sells a cast iron replacement for the 97- up tj with a 2.5.
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Old 10-28-2011, 11:22 PM   #11
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I have a 2.5 and it had a manifold leak, but mine were broken studs. I'd check that first.
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Old 11-06-2011, 10:16 PM   #12
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There is an updated part from the dealer on the studs and a new lock nut is included.
I did find that Omix-ada makes a nice replacement exhaust manifold for the 2.5's and I bought mine at rockauto.com they were cheaper than the other places. Not to mention the extra I paid in shipping it was still cheaper than buying from the dealer.
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Old 11-06-2011, 10:57 PM   #13
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My 2.5 had an exhaust leak a couple years ago that kind of whistled - especially once the engine warmed up. The fix was to tighten the two exhaust bolts closest to the fire wall. Each took about a 1/4 turn and the noise hasn't returned.
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Old 02-13-2012, 10:02 PM   #14
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Was driving yesterday ad heard a pop. Had the radio on and wasn't sure it was me. Then I heard a huge exhaust leak. I thought it was the gasket at the manifold to the head pipe. Turns out there is not a gasket there. Now im wondering if it is the exhaust manifold gasket, loose bolts, or cracked or blown out manifold. It is very loud so it is obviously a significant leak. Any input would be appreciated. Thanks
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Old 10-28-2013, 09:51 PM   #15
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Quote:
Originally Posted by jeffedmo View Post
I have an exhaust leak that's pretty loud until it heats up good and then it gets a bit better. I've been searching through the forums for info about this but all I really keep finding is info on the (apparently very common) 4.0 manifold issue. Before I run out and buy a new manifold, I thought I should check with you guys to see if the 2.5s have any known habits of cracking/warping too. Wasn't sure if I'm gonna end up with a bad manifold or just a bad gasket or seal. I'm having trouble determining exactly where the leak is located.
Im in the same boat with my 2.5 they do warp and crack. Im having issues finding the washers and bolts. Finding the manifold was the easy part.
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Old 10-28-2013, 10:05 PM   #16
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Im in the same boat with my 2.5 they do warp and crack. Im having issues finding the washers and bolts. Finding the manifold was the easy part.
Everyone on here told me it is impossible to wield em shut, and to buy a new one.. Being the penny pincher I am on such parts, I took it off.

I Sandblasted it, and then cut out the cracked grooves with a cutting wheel. ( 3 different cracks).

Took out my handy dandy mig wielder and filled them in. Good as new, no leaks. Then I painted it with cast iron paint, to prevent future rust
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Old 10-29-2013, 07:32 AM   #17
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Originally Posted by GingerTJ View Post

Everyone on here told me it is impossible to wield em shut, and to buy a new one.. Being the penny pincher I am on such parts, I took it off.

I Sandblasted it, and then cut out the cracked grooves with a cutting wheel. ( 3 different cracks).

Took out my handy dandy mig wielder and filled them in. Good as new, no leaks. Then I painted it with cast iron paint, to prevent future rust
Not imposible to weld, but it'll crack again cast gets brittle when welded on...
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Old 10-29-2013, 08:10 AM   #18
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Not imposible to weld, but it'll crack again cast gets brittle when welded on...
It's been 6 months, holding strong
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Old 10-29-2013, 07:21 PM   #19
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Quote:
Originally Posted by oldskool71 View Post
Was driving yesterday ad heard a pop. Had the radio on and wasn't sure it was me. Then I heard a huge exhaust leak. I thought it was the gasket at the manifold to the head pipe. Turns out there is not a gasket there. Now im wondering if it is the exhaust manifold gasket, loose bolts, or cracked or blown out manifold. It is very loud so it is obviously a significant leak. Any input would be appreciated. Thanks
I had the same pop noise on mine when I blew a hole in the to side of my exhaust. There were two holes the picture shows one and the other was under the heat Shield. Auto zone sells one for 115 and the gasket was 8 dollars. It took me about 3 hours to replace.
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Old 10-29-2013, 07:23 PM   #20
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Old 04-03-2014, 02:28 PM   #21
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jeffedmo

jeffedmo did you ever figure out what it was so I can have a idea what my problem is before I start taking it apart my jeep is doing the exact same thing once it warms up it goes away
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Old 09-25-2014, 05:58 PM   #22
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x2.... I have a noise comin from the lower backside of the motor. Jus curious on some potential causes.

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