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post #1 of 5 Old 08-17-2009, 09:16 AM Thread Starter
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1992 YJ Wrangler 
Join Date: Jul 2009
Location: cobleskill ny
Posts: 51
my header is cracked

How hard is it to remove the exhaust manifold on a 92 renegade 4.0. Does the intake have to come off? It looks like there are only 2 bolts, is there more that I'm missing? I see that the after market header is cracked where the pipes go into the collector. I bought the jeep with the header on it, I don't know the brand but the welds look real shotty. I also noticed there is no flex joint in the exhaust system at all. Does anyone suggest adding this in? Maybe right off the header on the down pipe? This would be out of the way when off roading,yet give some flex in the system so this won' happen again.

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post #2 of 5 Old 08-17-2009, 09:25 AM
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1991 YJ Wrangler 
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Location: Meridian
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Yes, the intake manifold has to come off as well. The intake and exhaust manifold share the same gasket and in many areas the same bolts and or studs. Seeing how you are in the rust belt, I would start soaking the bolts/studs with PB Blaster for several days before removal. Before beginning the work, inspect to see if any are missing so that you can have replacements in hand when you begin. There are replacement OEM style exhaust manifolds that come with baffles built in to help relieve the stress. This is a common problem with the exhaust manifolds cracking at the collector on the 4.0Ls.
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post #3 of 5 Old 08-17-2009, 09:28 AM Thread Starter
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Thanks for the info. I will start by soakng everything for days.How long do you think this would take with out air tools? Seeing that everything is rusted on this rig.
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post #4 of 5 Old 08-17-2009, 09:33 AM
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I don't think air tools will be an option. There just isn't enough room to get to most of the bolts. You need to be some what of a contortionist and use box wrenches and ratchets with universals. It will take a couple of hours and some choice words to get r done. Hopefully you won't break any of the bolts in the process, so budget time for that scenario before you begin.
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post #5 of 5 Old 08-17-2009, 09:34 AM
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Yea, avoid air tools for this. Hand tools will get it done, just take your time.

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