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Old 09-27-2009, 10:58 AM   #1
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Replacing an exhaust manifold

Hey there. I have a 99 TJ with a 4.0 and 5 speed that I need to replace the exhaust manifold on. It broke off right above the point where the tube splits on the underside. I've read that this is a pretty common thing for this year. I got 10 years and 140,000 miles out of the original so not too bad I guess. I've seen some on ebay for around $75 and was probably going to go ahead and pick one of them up. I did a search for a write up but couldn't find anything. Does anyone have a write up on this or has anyone done it and have any tips or tricks? Any help would be appreciated.

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Old 09-27-2009, 11:20 AM   #2
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Just get one with the expansion area's and you will be good to go. Not sure on a write up on here..

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Old 09-27-2009, 01:58 PM   #3
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  • Get a fuel disconnect tool, you'll need to remove the fuel line from the rail.
  • You don't need to remove the plastic cover over the fuel rail.
  • Invest in extra extensions and a universal to access the manifold bolts underneath.
  • Prior to reinstalling, screw the bottom bolts on just enough to catch on a few threads and install the manifold by having it sit on the bottom bolts.
  • Make sure the manifold is fully seated on the studs.
  • Use antiseize when reinstalling manifold.

Not a difficult, job. Installing my motor mounts was harder. I also purchased the $70 dollar eBay special and it's lasted me well for the past 3 years with no issues to date. I opted to purchase a better gasket (Fel-Pro) and threw away the Chinese gasket that came with the manifold.
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