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Topic Review (Newest First)
11-06-2013 08:23 PM
Springsblueyj Just went through this and wanted to ad what I had to do. I ended up snapping one of the bolts off of the flange. I spent the better part of the day soaking it with PB blaster and trying to wrench it out. I could not get it out. After taking the exhaust manifold off and trying with no luck, I took the hammer too it. Two whacks and it popped out. I have a 95, and apparently these bolts are not threaded in but have grooves. No matter how much you wrench it, it won't come out. It needs to be drove out like a pin. Hope this helps someone else out.
09-10-2013 05:00 PM
89Saharagreen Right on Jerricho glad to hear you got it worked out!

And yes jeep ingenuity is what we all use no matter the model or engine or lift or anything else.

Is why I love this forum even when I am not working on my jeep I can read posts here and learn about what I will be doing in a few weeks.
09-06-2013 06:43 PM
Jeeprich25 Turns out there's a piece of flange missing. Leaving a pretty huge gap between the pipe and manifold. So yes. I'll be replacing it. I don't throw good money after bad and I wouldn't waste the cash redoing the exhaust if it was a 12 flange gasket.
09-06-2013 04:55 PM
Jerricho
Quote:
Originally Posted by 89Saharagreen View Post

Jerricho please be aware if you have an exhaust leak at that junction it could be because your manifold is warped the gasket should at least help but it is thin and not designed to go there we are just using our collective ingenuity!

Chief
Isn't using our collective ingenuity exactly what we do as Jeepers? A praiseworthy pursuit if I ever heard one!

I put that gasket in albeit pretty cut down, and it appears to be holding for now, so *high five*
09-06-2013 09:58 AM
harleydragon
Quote:
Originally Posted by 89Saharagreen View Post
Guys


The 4.2 did not come with one the 4.0 did and the donut for the 4.0 will not fit the 4.2 the pipe diameter is different.

The 4.2 was designed not to need one the reason Jerricho wants one is because when he tightens his up he still has a leak.

The cat flat gasket if you cut the four corners off will fill the gap and resolve his problem.

Could he use a 4.0 donut maybe but the damn thing is thick and he would need to replace the studs in his manifold not to mention that the donut reduces the pipe down and so would restrict the exhaust flow.

Now the other jeeper with 2.5 not sure why he wants to replace whole exhaust.

Jerricho please be aware if you have an exhaust leak at that junction it could be because your manifold is warped the gasket should at least help but it is thin and not designed to go there we are just using our collective ingenuity!

Chief
I evidently got confused somewhere so if so just ignore my last post.I was talking about the pipe pictured with the donut in it
09-06-2013 09:42 AM
89Saharagreen Guys


The 4.2 did not come with one the 4.0 did and the donut for the 4.0 will not fit the 4.2 the pipe diameter is different.

The 4.2 was designed not to need one the reason Jerricho wants one is because when he tightens his up he still has a leak.

The cat flat gasket if you cut the four corners off will fill the gap and resolve his problem.

Could he use a 4.0 donut maybe but the damn thing is thick and he would need to replace the studs in his manifold not to mention that the donut reduces the pipe down and so would restrict the exhaust flow.

Now the other jeeper with 2.5 not sure why he wants to replace whole exhaust.

Jerricho please be aware if you have an exhaust leak at that junction it could be because your manifold is warped the gasket should at least help but it is thin and not designed to go there we are just using our collective ingenuity!

Chief
09-06-2013 08:24 AM
harleydragon picture shows that the end on both pipes are beveled so you don't need a gasket,just a donut.cut both bolts out,you may have to cut them or take big breaker bars and break them,take the old donut to the parts store and get as close as you can find to the same size and install them with new bolts as the guys described above.I was matching some up for corvette manifolds last week for a jeep and my local oreilly's had many different ones to choose from
09-05-2013 11:46 PM
bajajohn While you have the Exhaust pipe disconnected feel along the inside edge of the manifold if it is BEVELED it will take the donut type gasket. If the manifold and the Exhaust pipe both have a flat surface flange on them then it will take a flat gasket.
My 91 4.0 has the donut gasket on it.
09-05-2013 09:05 PM
sfhusser Supposedly there exists an exhaust paste that you smear around the inside of the down pipe, but I don't know what it is. If anyone is a fan of Wheeler Dealer on the Velocity Channel they (Ed) uses it a lot. Been trying to find it here. It (for those not familiar with the show) is filmed in England.
09-05-2013 08:03 PM
87 Florida YJ
Quote:
Originally Posted by Jeeprich25 View Post
Just tried installing a new flange gasket on my 2.5. Wouldn't fit. Studs are way too short and no room for one. Now the jeep sounds like a lawn mower due to the leak. Guess its time for a new exhaust system. Ugh.
Jericho you are making more of this than necessary. There are two studs right? If they are 'way too short' just buy two longer ones. The donut is just a ring of lead right? Take the old one with you to the parts store. If you can't get one exact then get one thats close (larger) because that's all it has to be. Put the donut in the middle and start torking down the studs equally a little at a time. crank it down as tight as you can by hand. It's going to work. Then send me half of the money you would have pissed away on a new exhaust system.
09-05-2013 07:48 PM
Jeeprich25 Just tried installing a new flange gasket on my 2.5. Wouldn't fit. Studs are way too short and no room for one. Now the jeep sounds like a lawn mower due to the leak. Guess its time for a new exhaust system. Ugh.
09-05-2013 06:31 PM
Jerricho Chief,

Yes, I am going to give the gasket a go and hopefully that gets it. I will post to let everyone know, so the 4.2 people can have some info saved.
09-05-2013 10:04 AM
89Saharagreen So did you not want to cut the square one for the cat to fit there at the manifold?

It is cheap simple and easy just cut the four corners off the diameter of the hole is the same and the heat will help it conform better after you tighten the bolts.

Just re-tighten after you run it for a bit and you should be good to go.

I did replace my bolts with stainless steel ones and did use liberal anti-seize but other than that nothing different than what has been previously posted

Chief
09-05-2013 12:26 AM
Jerricho
Quote:
Originally Posted by Mbclark View Post
X2 none needed. Carbon will fill gaps after you've ran it a bit. Just make sure everything is lined up properly and it'll seal. It also helps to tighter each bolt down a little at a time, few turns on one then a few turns on the other, this ensures everything stays lined up while you're tightening.

I have to do something, I have not had that pipe off in 2 years, and it is leaking, so I don't think it will get plugged with carbon. I tightened the bolts down just about as far as I could without breaking them. I may have to just resort to the RTV, man I hate when things don't work like they are supposed to.
09-03-2013 04:27 PM
Mbclark
Quote:
Originally Posted by 89Saharagreen View Post
4.2 does not have a gasket there you can make one out of the four bolt one for the cat but it never came with one from the factory only 4.0 did and I think the 2.5l and the donuts for them don't fit pipe size is different.

Just went through this myself.

Chief
X2 none needed. Carbon will fill gaps after you've ran it a bit. Just make sure everything is lined up properly and it'll seal. It also helps to tighter each bolt down a little at a time, few turns on one then a few turns on the other, this ensures everything stays lined up while you're tightening.
09-03-2013 04:20 PM
Jerricho Chief,

Did you just make one? I have a leak there even after tightening the bolts down. I suppose I could just put some high temp exhaust rtv in there and pray for the best, but would rather use a gasket if there is one that fits.
09-03-2013 03:56 PM
89Saharagreen 4.2 does not have a gasket there you can make one out of the four bolt one for the cat but it never came with one from the factory only 4.0 did and I think the 2.5l and the donuts for them don't fit pipe size is different.

Just went through this myself.

Chief
09-03-2013 03:47 PM
94 Sahara Ga It's worth a shot to see if it work's. especially if your pipe flange looks the same.
09-03-2013 02:46 PM
Jerricho I have the 4.2, and they don't list that one as fitting, though it looks correct. They keep trying to sell me the 4 bolt one that goes in front of the Cad Converter.

It is not hard to change, maybe I will just go tell them I need that one and see if it fits. I imagine it should.
09-03-2013 02:14 PM
redneckbrat Thanks, getting some pb blaster after work, I got mine at autozone too
09-03-2013 12:18 PM
TeeJayy x2 on the anti seize, mine were so rusted up i had to cut them off
09-03-2013 12:15 PM
wasomma It's super easy to change, like what was mentioned before soak it in PB blaster over the course of a few days, have some spare hardware just in case you break a bolt.

Make sure you check the fit after it has been through a couple heat cycles. Once it gets hot and the gasket crushes a bit you may need to re tighten the bolts
09-03-2013 12:04 PM
94 Sahara Ga I bought one last week from autozone. This is what I bought from Autozone.
http://www.autozone.com/autozone/par...=225399_0_5901_
09-03-2013 11:43 AM
AllMudd
Quote:
Originally Posted by Jerricho View Post
Where did you get the gasket? I have been looking for it, and AZ only sells it in the pack with the intake manifold gasket. I am not paying $26 for a $2.50 gasket.
Qtec has them. I just bought mine from Oreilys. Ill post the part number when I get home.
09-03-2013 10:16 AM
Jerricho Where did you get the gasket? I have been looking for it, and AZ only sells it in the pack with the intake manifold gasket. I am not paying $26 for a $2.50 gasket.
09-03-2013 07:57 AM
redneckbrat
Quote:
Originally Posted by 2xs View Post
Did you get it fixed?

Did you did a place open Monday?

Did you pass?
I didn't do it. Found out that I have more time. I went wheeling instead at Prairie City.
09-03-2013 12:32 AM
2xs
Quote:
Originally Posted by redneckbrat View Post
Thanks guys. I have to do this tomorrow so I can finish smogging it on Monday. I hope this fixes it.
Did you get it fixed?

Did you did a place open Monday?

Did you pass?
08-31-2013 09:08 PM
redneckbrat Thanks guys. I have to do this tomorrow so I can finish smogging it on Monday. I hope this fixes it.
08-31-2013 09:06 PM
bajajohn Make sure you have a couple extra nuts and bolts laying around just in case. when I did mine I broke one and had to do a 34 mile round trip to town to get a new bolt.
The way the exhaust pipe curves under the oil pan is not really a good design. it looks like it hangs down too far.
08-31-2013 08:26 PM
Mowrangler Looks like a donut gasket to me.Hardest part is getting the 2 nuts off the studs, soak them liberally for a few days with PB Blaster before you attempt dissasembly otherwise you risk breaking the studs off.Do yourself a favor when you put it back together liberally apply anti-sieze to the studs it will make future dissassembly much easier.
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