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hey i have a 03 TJ 4.0L that im doing a JBA header install on pretty soon. I heard that breaking header bolts is almost a guarantee. Does anybody know any tricks to try and prevent this from happening? I'd really like to not have to bring it into a shop and blow hundreds of dollars that i dont have :banghead: .
 

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Get the engine warmed up first, then crack them loose. Worked on my mustang header bolts.
If you could do that and then spray something cold just on the bolts that might make them contract enough to help? maybe
 

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Mine looks like it would be easy enough. its a 4.0
I havent looked under the hood in a while so not sure
 

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With the engine cold, spray the bolts with Break Free, Liquid Wrench, PB-Blaster, etc. and let it soak into the threads. Then spray 'em again and go off & get a burger or something to give the penetrent time to work into the threads. NO, WD-40 is not a suitable substitute for any of those.

Take great care to get the intake manifold properly re-positioned before tightening its bolts. If you don't, you'll end up with a vacuum leak between the head and intake manifold and you'll have sky-high engine rpms when you start the engine. Look for the little positioning studs to help get it positioned properly.
 

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Mine went on just fine without broke bolts, but I had had the head off at least once per year for the two or three years prior to installing the header. Hitting it the night before with PB-Blaster can't hurt...
 

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Discussion Starter #8
im gonna just try and soak the bolts with pb-blaster for a day or two. i talked to my mechanic friend about it and he was saying at least 2 bolts are breakin on the way out but we'll find out i guess
 
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