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naviathan 11-16-2005 03:13 PM

Exhaust Leak
Got an exhaust leak just behind my CAT and the exhaust bracket right before the cat broke (I think that caused the leak). Anyhow, I need to get at the whole exhaust system, but it looks like the transmission skid plate is in the way. Can anyone suggest an easy fix. Aside from a muffler shop of course. That one is pretty obvious.

4Jeepn 11-16-2005 03:56 PM

If you have enough room you may be able to weld it closed. but it all depends on the location of the leak. Also can you un-hook the back section of the pipe and get it out to replace or repair it with out having to unbolt the skid plate?

naviathan 11-17-2005 07:42 AM

That's what I'm hoping I can do, but I've never dealt with a Jeep before so I don't know if there's enough room to get in there and do what needs to be done. I'm hoping the leak is only from the cat back, but I'm wondering now if it's leaking before it also. the whole exhaust system looks like it's about fall apart from rust.

naviathan 11-17-2005 03:06 PM

Ok found my leak, it's actually the header that's making all the noise. Right before the collector where it goes from 2-1 one side is completely cracked all the way around. Explains the popping sounds also. I think I can get a mig up there and seal it up though.

jeeperman 11-17-2005 04:29 PM

That is a huge problem for all of the YJs and some TJs if I remember correctly. I haven't experienced it in the latest Jeep, but it's not old enough yet...

4Jeepn 11-17-2005 04:34 PM

yeap, the header area issue is a major porblem...have to get my 97 fixed as it has it now.. from what I understand you can buy a aftermarket one that has expansion joints for lack of the reat term around $200 or so, vs the jeep one which is 2 or 3 times that much.

1BLKJP 11-17-2005 05:00 PM

It was a problem for all 91-99 4.0L engines. Bad design of the exhaust manifold on top of crappy materials.

naviathan 11-21-2005 07:55 AM

Well I welded it up. Still need a cat back exhaust (muffler is rusted inside and ate through the baffle). Seems to be holding so far, but it's not pretty. Getting my big hands under the intake and still move around enough to weld wasn't easy. It's still popping some though so I sprayed around the intake with carb cleaner and it idled down when I hit the 5 and 6 intake runners. I think it's the o-rings for the injectors though. Any thoughts?

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