I know the Manifolds are prone to cracking, Have a 98 TJ 2.5, is there a fix to this or just something we live with?
See mine was too far gone i guessI have a 98 4.0l with cracked exhaust manifold and took it to the local exhaust shop. He does jeeps the majority of the time so knows where they crack. He welded inside and out on all the spots it has cracked or would crack and has never had one been brought back. Costed a tad over 200 and havent had a problem in a few months now.. Just another opinion. If it cracks again ill just buy the new one with flex joints but for now mines great and saved me some money
Check the down pipe bolts before you install. The nuts weren't cut right and wouldn't go all the way down. Had to replace them with some replacements from Ace.It's not something you can just live with and it can't be repaired. The only fix is to replace it with a replacement header like you can get from Amazon.com or eBay.
Look for a replacement like this one that has flexible steel expansion joints like the below replacement header... they allow it to flex instead of crack. And no, the cracks can't be welded since the header will just crack again right next to the welds. Engine torque flexes the header which causes the cracking.