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You are dealing with a common problem with the 4.0L engines. They go through a LOT of headers/exhaust manifolds. You would think that after 15 years Jeep would figure it out, but they didn't. Just go with a well known company that has a great warranty. You most likely will have to replace the new one again eventually, but hopefully not for a few years!
 

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First we should figure out why the ones you are replacing have cracked so often. What have you been putting on there? Because the newer version of the exhaust manifold from 2000 on up haven't had the problems that the 91-99 4.0 manifolds had.
 

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1BLKJP said:
First we should figure out why the ones you are replacing have cracked so often. What have you been putting on there? Because the newer version of the exhaust manifold from 2000 on up haven't had the problems that the 91-99 4.0 manifolds had.
Exactly. My '97 TJ is on its 4th header but the last one the dealer installed just before the warranty expired was the newer crack resistant style and it has held up just over 100K miles now. The first three older design headers cracked within 36,000 miles.
 

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Discussion Starter · #6 ·
the first one that broke was stock and the other one's came from auto zone witch had flex inserts on the outter tubes..But they all three broke in the same place witch was at the top of the collector???? Maybe a whole new exhaust system is the answer
 

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cueball said:
Maybe a whole new exhaust system is the answer
Nope, the rest of the exhaust wouldn't cause this problem. You've had three from Autozone fail, I'd think that is a huge clue that Autozone's design is bad even though it has the flex joints. My redesigned factory header, as I said above, has held up fine for 100K miles now. Three of the older design headers failed on my TJ within 36K miles. Banks reputation on TJ headers isn't so good either so I would also avoid that brand.
 

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cueball said:
THANK'S I'll give that a try
I get them from the dealer dont i ?????????
Try a few dealers and NEGOTIATE with them, you'd be amazed at the wide range of prices different dealers will quote for the exact same part.

But first, check out http://www.chryslerpartsdirect.com/moparonline.htm which may be the cheapest easiest way. Good luck.
 
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