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Old 03-11-2014, 10:42 PM
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Exhaust to Headers 99 wrangler

Hey all! I own a 99 Wrangler, I heard a exhaust leak so I took it in for a check and they said I needed a new Exhaust manifold, flowmaster and tailpipe. They estimated me at $900 plus tax. I started thinking why not do headers instead!

So I guess my big questions are what would you guess suggest, I am on a budget but don't want crap. I still need to pass Emissions. And what all I need to get to do the swap.

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Old 03-12-2014, 09:14 AM   #2
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go to the junkyard and pull the two-piece cast exhaust manifolds off a late model WJ or XJ. then get Walker Exhaust PN#s 52317, #16085 and a Walker or Dynomax cat back from Summit Racing.

Half the price, bolt up, will be all new from the engine back & you can do it all yourself.

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Old 03-22-2014, 06:32 PM   #3
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I'm in same situation with my 98 TJ. Exhaust leak at the manifold, and considering headers and cat-back aftermarket muffler... I don't want an obnoxious sound, but something a little different than stock would be cool. I dont know which way to go. decisions decisions...lol
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Old 03-22-2014, 06:54 PM   #4
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The 4.0L engine in a TJ comes stock with headers, you will not see any performance boost with an aftermarket header.

I would just go to eBay and find a header like the below which has the flexible steel bellows added which stops the cracking. I went through 3 cracked headers within my then brand-new '97 TJ's first 3 years before installing one like the below in my previous TJ. I had no more cracked header issues my TJ's final 165K miles before it was stolen.

Notice the flexible steel "accordian joints" circled in red...

Keep one VERY important thing in mind while installing new headers... take your time to get the intake manifold properly seated over the short positioning studs on the head. If you don't, the intake manifold WILL leak and cause your engine rpms to redline as soon as you start it. Then you have to start the job nearly all over again.
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Old 03-22-2014, 07:59 PM   #5
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... find a header like the below which has the flexible steel bellows added which stops the cracking...
Jerry,
Why does the manifold crack at that point? If the flexible steel bellows prevent the cracking, you'd think that Jeep would learn from their mistake, & install the flexible steel manifold instead. What years of the TJ are prone to this cracking?
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Old 03-22-2014, 08:37 PM   #6
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If you don't, the intake manifold WILL leak and cause your engine rpms to redline as soon as you start it. Then you have to start the job nearly all over again.
Hum, you aren't talking from experience are you???
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Old 03-22-2014, 08:37 PM   #7
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Jerry,
Why does the manifold crack at that point? If the flexible steel bellows prevent the cracking, you'd think that Jeep would learn from their mistake, & install the flexible steel manifold instead. What years of the TJ are prone to this cracking?
Jeep did learn from their mistake, they released the redesigned header in mid-'99 to include flexible joints like are are in that photo. '97 to mid-'99 have the cracking header problem. It cracks there from engine torque as the engine moves around on on its mounts.

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Hum, you aren't talking from experience are you???
Actually no but it happens at least once a week on one of the two forums I frequent. Higher than normal engine rpms from vacuum leaks are pretty common, redline rpms from a mis-seated intake manifold are nearly as common.
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Old 03-22-2014, 09:17 PM   #8
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Mine cracked in the middle where the two main pipes meet. Would this flexible thing still help that?
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Old 03-22-2014, 10:34 PM   #9
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Jeep did learn from their mistake, they released the redesigned header in mid-'99 to include flexible joints like are are in that photo. '97 to mid-'99 have the cracking header problem. It cracks there from engine torque as the engine moves around on on its mounts.
Was there a factory recall on this?
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Old 03-22-2014, 10:36 PM   #10
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No, recalls are only for safety related reasons.
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Old 03-23-2014, 07:39 AM   #11
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I just installed 1 Just Like Jerry's Picture on My 97 4.0 Yesterday I got it off eBay for around $85 with Free Shipping Fit Just Fine, I recommend Not using the Cheap Gasket that comes with the Header I Purchased a Fel-Pro Gasket From My Local Parts store,You will also want to Pick up a set of Fuel Injector O-rings as the Fuel Rail/Injectors will need to be removed when removing the Intake Manifold.
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Old 04-03-2014, 07:19 PM
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Thank you everyone for the input! 😃

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