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Old 03-10-2013, 07:39 PM   #1
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Jeep keeps cracking headers. What gives?

Onto my 3rd header on my wrangler. The PO replaced the stock one when I bought it. That one cracked at multiple points shortly after I bought it. I replaced it with one of the stainless steel ebay headers with the flex joints that I heard a lot of guys used on this forum. Now I have yet another crack at the collector where one of the pipes come in. By the sounds of it, I'm sure i have even more cracks that i cannot see. My question is, what could possibly be causing this? My motor mounts seem to be in good condition. The rubber looks good and they are tight. I revved the engine and it doesnt rock back and forth much at all. Does anyone have any advice? Anyone else with this kind of bad luck? I'm about to bite the bullet and try a banks or jba header but those dont even have the flex joints. It looks like the collector design is different though. Any advice is definitely appreciated. I'm beginning to forget how a vehicle without leaky exhaust sounds.

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Old 03-10-2013, 07:40 PM   #2
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also, its a 99, 4.0 (shouldn't really need to specify lol)

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Old 03-10-2013, 07:42 PM   #3
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I got a '97 with 2.5l 4 banger I replaced the header on about 5k miles ago. I think I heard it leaking this weekend while under the hood already......I'll follow for advise also.
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Old 03-10-2013, 07:44 PM   #4
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This is the one I put on my 98 and it's working quite well so far. I've had it three months now, no complaints

http://www.amazon.com/Dorman-Solutio...sim_sbs_auto_1
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Old 03-10-2013, 08:28 PM   #5
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go to the late model stock two piece cast manifold style. Use a Walker #52317 Exhaust Pipe to connect it to your cat and you should be done.
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Old 03-10-2013, 08:46 PM   #6
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Do you know where I would look for the two piece design? Probably a dealer part or ebay?
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Old 03-10-2013, 11:39 PM   #7
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Quote:
Originally Posted by JeepinDave View Post
Do you know where I would look for the two piece design? Probably a dealer part or ebay?
ebay, dealer, new from RockAuto, or junkyard. if going junkyard, look at 00-04 WJ, 00-06 TJ or 00-01 XJ with I-6.
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Old 03-11-2013, 12:26 AM   #8
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Had the same problem with my 97 TJ. 4.0. In the first 50,000 cracked 2 headers (both replaced under wrty by dealer). Cracked again, by that time I was fed up. I bought a Banks system (dealer handled the labor no charge). Banks lasted 140,000 miles. It just started to crack down by the collector. I've talked to Banks and they are going to warranty it. They're sending me their new "Revolver" model. The rep said they've run into some high mileage cracking in that area, that's why they did the redesign and reinforced that area on the Revolver. I've been very pleased with Banks customer service. The labor really isn't going to be a problem as i'm rebuilding my engine at the same time. So I either go with Banks or the newer 2 piece from Jeep.
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Old 03-11-2013, 07:08 AM   #9
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Thanks unlimited and marrk. I've got some researching to do. I appreciate the responses.
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Old 03-12-2013, 01:48 PM   #10
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I have a 98 4.0 cracked 3 factory headers went with a borla in 2007 put 125k miles on it. Changed my engine to a stroker motor 10k on it. No problems.
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Old 03-13-2013, 10:07 AM   #11
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Update.. Just bought the 2 piece design off eBay for 50 bucks. Came off a 4.0 WJ. As for the walker downpipe, it looks like my cat isn't bolted up but instead welded in place. I imagine I'm going to have to have the exhaust shop re weld my cat in with the new downpipe.
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Old 03-13-2013, 10:22 AM   #12
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Originally Posted by JeepinDave View Post
Update.. Just bought the 2 piece design off eBay for 50 bucks. Came off a 4.0 WJ. As for the walker downpipe, it looks like my cat isn't bolted up but instead welded in place. I imagine I'm going to have to have the exhaust shop re weld my cat in with the new downpipe.
You might need to weld an exhaust extension in.
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Old 04-28-2013, 11:02 PM   #13
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revolver cracked

My 99 4.0 has the banks revolver on it and now about 10k miles later, busted...I'm going to get an eBay flexy special and see how that works. I'll probably get banks to fix my revolver and just keep it for a backup.
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Old 04-30-2013, 06:15 AM   #14
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I went with the flex eBay style and didnt last me even 10k. I'm convinced the only true fix is the 2 piece cast iron route. I'm still collecting new parts here and there and waiting for a good time to install it. I should have less than 200 bucks wrapped up In it.

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