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Old 10-26-2010, 12:52 PM   #1
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look what I found, cracked header

I took off my header cover a bit ago so I could get at the bolts on the flange to tighten/replace them because the flange is loose and flopping around where it connects the cat/exhaust pipe to the headers. Well come to find out my headers are cracked. 2006 2.4L

1. How does this happen with only 60k miles?
2. how will this affect drive ability if I don't replace it right away?
3. can I pass inspection like this (we have emissions testing here)
4. any suggestions on a replacement brand so this won't happen again? Something that won't break the bank hopefully.
5. what should I do?


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Old 10-26-2010, 01:54 PM   #2
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is it leaking?
it could be just outside.
usually when metal is hot then suddenly cool down it becomes brittle.

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Old 10-26-2010, 02:02 PM   #3
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how do I tell if it's leaking?
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Old 10-26-2010, 04:46 PM   #4
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Put your finger over the crack while its running.....
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Old 10-26-2010, 04:51 PM   #5
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I will try that tomorrow thanks.

Regardless if it's leaking or not should it be replaced before it gets worse? What can happen if I drive around with a cracked header?
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Old 10-26-2010, 05:11 PM   #6
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The header will continue to crack, and it will sound like you are not running any exhaust at all. Fuel mileage will plummit and there will be a very noticeable loss of power. Some say that you can also burn a valve in the engine. It's really not good to run it like that for a long time. I also would not try to repair. The parts aren't expensive to replace and it is a good job to try yourself.
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Old 10-26-2010, 05:43 PM   #7
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Thanks, I'm sure I can handle it myself I've always done all my auto work since I was kid just short of dropping a transmission or pulling an engine. What do you suggest I replace it with? OEM or after market headers? If I put on anything other than OEM will I have to replace my stock exhaust? any suggested places to find them at a decent price?
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Old 10-26-2010, 06:56 PM   #8
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I'm not that familiar with the 2006 4cyl. Do you have the two piece exhaust? If so, go back with that. If not, you can upgrade to it as many of us with older one piece exhaust do. The two piece is far less prone to cracking. If you use a one piece exhaust, get an aftermarket exhaust with the expansion bellows as it MAY not crack as easily.
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Old 10-27-2010, 02:37 AM   #9
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When you said the parts are not expensive were you referring to buying another stock header? haven't done much research yet but it seems what I have seen have been more than a couple hundred bucks.
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Old 10-27-2010, 02:45 AM   #10
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I got my one piece manifold with expansion joints off e-bay for less than 100.00. I think about 80.00.
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Old 10-27-2010, 02:49 AM   #11
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Is it a manifold or a header I'm looking for? do you remember what brand you got? I don't want something cheap that will crack again. I'm pretty sure I have a one piece exhaust, where does the two piece exhaust separate?
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Old 10-27-2010, 04:12 AM   #12
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Unfortunately they ALL will crack again unless you do some other things as well. First check your motor mounts if you blip the throttle and the engine moves excessively your motor mounts are worn out and all the flexing will put stress on the manifold and will help with the cracking. You should get some type of flex pipe installed before the cats down stream of the manifold to give the notoriously stiff exhaust system some much need room to move as well. I've done this along with installing an aftermarket header and for the first time have not had any more issues with the cracking manifold.
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Old 10-27-2010, 04:20 AM   #13
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what do you mean by flex pipe. I only have 60k miles so I hope my motor mounts are not warn out because I just installed JKS motor mount spacers. Maybe I should have went with the full bombproof motor mount lift.
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Old 10-27-2010, 10:17 AM   #14
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The one I have has bellows type expansion joints on a couple of the pipes coming off the block. Search TJ exhaust manifold on e-bay and it will be obvious when you see it. Could you take a pic farther from the engine showing the whole header/exhaust manifold? Sure looks like you have the two piece design.
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Old 10-27-2010, 11:34 AM   #15
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Well I did some some looking around I have a 97 tj 4.0 and I have the same problem I would say go with a banks header 425$ lifetime replacement this is a very known problem for the 4.0 so spend the money so if and when it cracks u get a new one by the way the 2 pice is only for 99 and up and don't IMO don't by cheap parts u get what u pay for hope this helps
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Old 10-27-2010, 12:49 PM   #16
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My exhaust manifold I just bought replaced the original. The original was 12 years old. If I can get even 10 yrs out of the replacement at 80.00 apiece, thats 50 years for less than the Banks at 425.00 a pop!!! Hope my Jeep makes it 50 years...lol. J/K with ya though, the Banks is a good header, but most will usually crack anyway.
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Old 10-27-2010, 01:20 PM   #17
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a cheap effective fix , silver solder and i don't mean with a soldering gun i mean by a torch . it is shown on youtube or 80 bucks at ebay gets you a new one . my TJ had this problem so i tig'd it and reinforced the pipe
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Old 10-27-2010, 01:35 PM   #18
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But does the 80 improve performance? Even of it adds 5hp to the jeep I think every one knows the 4.0 should have more power or maybe that's just me
"Banks test reports have shown that when the Stinger is used with their new Torque Tube header system, you'll see a gain of at least 25 horsepower banks websight"
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Old 10-27-2010, 01:39 PM   #19
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exhaust manifold

Quote:
Originally Posted by ohsixteejay View Post
I took off my header cover a bit ago so I could get at the bolts on the flange to tighten/replace them because the flange is loose and flopping around where it connects the cat/exhaust pipe to the headers. Well come to find out my headers are cracked. 2006 2.4L

1. How does this happen with only 60k miles?
2. how will this affect drive ability if I don't replace it right away?
3. can I pass inspection like this (we have emissions testing here)
4. any suggestions on a replacement brand so this won't happen again? Something that won't break the bank hopefully.
5. what should I do?

this looks like cast iron (manifold) have you seen if hooker or hedman makes a header ? the 2 best header manufacturers
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Old 10-27-2010, 02:04 PM   #20
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Quote:
Originally Posted by Jeepfreak83 View Post
But does the 80 improve performance? Even of it adds 5hp to the jeep I think every one knows the 4.0 should have more power or maybe that's just me
"Banks test reports have shown that when the Stinger is used with their new Torque Tube header system, you'll see a gain of at least 25 horsepower banks websight"
No, and neither does the Banks. Those numbers are from a tuned car on a dyno at RPMs that your Jeep will never see. There are soooo many test of different intakes, headers, air intakes, etc that have been done and documented on the Jeep motor. The consensus is that short of internal motor improvements (stroker), the cost/horespower ratio is way out of balance on the cost side.
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Old 11-04-2010, 08:19 PM   #21
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I will be putting a banks on mine soon I plan on keeping my jeep and just saying lifetime on a part that goes bad on this motor is not a bad idea.
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Old 11-05-2010, 09:02 AM   #22
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IMO... only use the one on ebay with the expansion joints built it. Ive heard of Borla headers cracking... Its a flaw in the original design of the header... Heard someone say something about the different lengths of pipe expanding at different lengths causing the break. I could care less if they will replace the $425 header for free... The problem is having to do the work again... Install the one with the joints in it and youll never have a problem again.
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Old 11-05-2010, 03:39 PM   #23
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The joints are for A 99 and up tj
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Old 11-12-2010, 06:32 AM   #24
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And the expansion joints crack too.
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Old 11-17-2010, 12:28 PM   #25
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I would stay clear of the Banks. I replaced my OEM a few years back and thought the Banks was the way to go. A year later, it was cracked again. Thinking I got a lemon, I replaced it with another Banks header. That one lasted only a few months. I called Banks and they informed me they have an issue with the welds they can't figure out, basically it will just keep happening. On top of that Banks just doesn't replace it you have to buy a new one and send yours back in (unless you can let your jeep sit for months) while they make sure it wasn't an issue or over heating or outside stress (bad mounts ). I was away at school so I paid to have them put on and the lifetime warranty doesn't mean much to me when I have to pay $400 in labor to have it put on every few months. Banks WILL NOT pay for the labor no matter how much you b*tch, believe me I tired and threatened to bash their product on every jeep forum I could find.
Awesome when you pay all this money on aftermarket products to make you Jeep look/perform better and something like this makes it sound like a total piece of sh*t!
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Old 11-18-2010, 09:25 PM   #26
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Quote:
Originally Posted by ohsixteejay View Post
I took off my header cover a bit ago so I could get at the bolts on the flange to tighten/replace them because the flange is loose and flopping around where it connects the cat/exhaust pipe to the headers. Well come to find out my headers are cracked. 2006 2.4L

1. How does this happen with only 60k miles?
2. how will this affect drive ability if I don't replace it right away?
3. can I pass inspection like this (we have emissions testing here)
4. any suggestions on a replacement brand so this won't happen again? Something that won't break the bank hopefully.
5. what should I do?

the auto makers depend on these parts breaking ,if you look inbetween the manifold you will see sharp edges in the casting thats where the crack started now if they had taken it and rounded it it would not have cracked , soooo when cast iron expands and contracts it stress's the casting and add water to that a sure fire way for it to crack. if they made his part from cast steel then they'd have parts they'd never sell ! so if you use a cast one die grind the sharp edges off . also had this problem with my 4.0 header the radius's that are bent in the pipes are so tight that the grain in the steel is stressed add water crack . so i took my header and mig'd all the tubes together and it reinforced it .also the cheap crappy steel tubeing was a factor in this equasion
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Old 11-19-2010, 03:04 PM   #27
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Quote:
Originally Posted by 1999_Wrangler
I would stay clear of the Banks. I replaced my OEM a few years back and thought the Banks was the way to go. A year later, it was cracked again. Thinking I got a lemon, I replaced it with another Banks header. That one lasted only a few months. I called Banks and they informed me they have an issue with the welds they can't figure out, basically it will just keep happening. On top of that Banks just doesn't replace it you have to buy a new one and send yours back in (unless you can let your jeep sit for months) while they make sure it wasn't an issue or over heating or outside stress (bad mounts ). I was away at school so I paid to have them put on and the lifetime warranty doesn't mean much to me when I have to pay $400 in labor to have it put on every few months. Banks WILL NOT pay for the labor no matter how much you b*tch, believe me I tired and threatened to bash their product on every jeep forum I could find.
Awesome when you pay all this money on aftermarket products to make you Jeep look/perform better and something like this makes it sound like a total piece of sh*t!
Man if this happened for real to you I am thanking twice about that header mine is cracked on my 97 4.0 and I just been driving it like that. I'll do more research before I buy mine I am open for suggestions

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