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Oozing machismo 05-05-2013 07:58 PM

Exhaust Manifold replacement - Who has done it?
I currently have the oil pan dropped as I am replacing the oil pan gasket and the rear main seal. I know I need to replace the exhaust manifold in the future as it is badly rusted and looks like there is a small hole in the split. So is it easier to replace the exhaust manifold while the oil pan is off? Is it doable to replace it when the oil pan is on? I'd rather not replace the manifold now if possible do to money, but if it is that much easier to do it while the pan if off, then I will.

Abomination93 05-05-2013 08:53 PM

People wool want to know which engine you have.

I know on the 4.0l you don't have to drop anything. I would venture a guess the 2.5 and 4.2 are in the same boat.

Oozing machismo 05-05-2013 09:03 PM

Good call, sorry. 4.0L

DJ_Marc 05-05-2013 09:21 PM

Also before dropping $200 go to a junk yard the manifolds off a cherokee will fit a wrangler just match up the years only cost $20 there

spyder98 05-06-2013 03:22 PM

i paid $90 for mine off ebay. Still havent installed as im gathering all the pieces im replacing all my exhaust

bajonesy77 05-06-2013 06:47 PM

I have the 2.5 and need to replace mine, do the bolts usually come out or are they gonna just going to snap off. The whole things looks rusted and is leaking in the back but can't see where exactly.

Oozing machismo 05-06-2013 08:53 PM

I am also worried about the bolts snapping out. Is this is a common occurrence? The manifold looks extremely rusted.

Bart113000 05-07-2013 08:03 AM

I replaced mine on my 4.0. I am a novice mechanic and was able to do it with a $90 manifold off took me about 9 hours to complete. I followed the following thread and had no problems. I would highly encourage you to remove the front quarter panel for easier access.

How-to: Replace your cracked exhaust manifold -

Oozing machismo 05-07-2013 11:39 AM

Hey Bart,

How rusted was your manifold? Did you have trouble with the bolts?

CMike357 05-08-2013 01:54 PM

Replaced mine a couple of years ago with SS header I got off Ebay for about $125. Took my time with it and took about 4 or 5 hours. I thought I would have problems with bolts but they all came out fine. Immediately noticed improved performance, but I was replacing a cracked stock exhaust manifold. Its not that difficult, just take your time and it is a good idea to take pictures of the area for reference when hooking everything back up. It is also a good time to inspect everything while you have it off, the intake manifold has to come off and you can inspect your valves for any build up on them.

Bart113000 05-08-2013 07:16 PM

It was pretty rusty and I had a large crack. I had a little trouble with a couple bolts taking off the quarter panel, but no issues with the manifold bolts.

Oozing machismo 05-08-2013 08:23 PM

Did the oil pan get in the way? I currently have the oil pan dropped. Any benefit to replacing the manifold while the oil pan is off?

xjrjrx 05-08-2013 08:37 PM

Probably not I changed mine in like 2 hours without removing fenders or anything like that just followed my Haynes manual and got it done in no time bolts were rusty as all get out but didn't have any problems with any of them

Bart113000 05-09-2013 07:02 AM

I did not remove my oil pan...xjrjrx, if you did this in 2 hours you are a much more experienced wrencher than I am! From what I have read...6 to 9 hours is about the average time you should expect.

Bart113000 05-09-2013 07:03 AM

Also, I did not find the Haynes manual very helpful for this process!

MikeDSC 05-09-2013 11:12 AM

I did my exhaust manifold about a year ago. The oil pan is not an issue at all. Took me and a buddy about 2.5 hours to do. Found out when I was removing the mainfold that there was only one bolt holding it in on the bottom. Could explain why my MPG's were terrible and the Jeep was LOUD. After a new gasket and some new bolts, it was like driving a totally different Jeep.

xjrjrx 05-09-2013 11:27 AM

The only real problem I ran into when I did it was my vacuum lines were in bad shape and I had to replace them cause I broke two of them I also researched it a while before doing it when I saw how long it said it would take I almost brought it somewhere

1ATony 05-09-2013 03:11 PM

We carry a 4.0 exhaust manifold that's new with free shipping. Here's a link to them for a YJ on our website.

Wrangler Exhaust Manifold 4.0

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