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Unread 11-15-2005, 11:17 AM   #1
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Join Date: Apr 2005
Location: USA
Posts: 27
4.0 Exhaust Manifold

I have a 99 Wrangler 4.0 with a crack in the lower end of the exhaust manifold, near the O2 sensor. The dealer want's $1,100 to replace it. Can it be welded?

If not, how about these $120 aftermarket stainless steel ones, will they swap out OK (California model ?) Chiltons manual says to remove the fuel injectors in the process. Is it neccesary to tamper with the injecters in order to get to the manifold bolts (nuts).


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Unread 11-15-2005, 08:02 PM   #2
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1991 XJ Cherokee 
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Location: Denver, CO
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Because the same 12 bolts hold the intake AND exhaust in, when you take 'em off the whole thing falls apart. As far as the injectors, you won't if you're careful. I did my headers and just unbolted the big bolts, which are a PAIN to get to. I say, if you've got to replace it, get nice headers. I got a set of pacesetter headers for $225 shipped. got 'em on eBay.
"Nitrous? So is that like viagra for your Jeep?" -mom

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Unread 11-15-2005, 11:10 PM   #3
wyllie YJ
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2001 TJ Wrangler 
Join Date: Nov 2005
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wyllie YJ

I had a similiar problem and had to replace mine. I couldn't see spending $800-$1000 so I decided to try it myself. I'm no mechanic but with a good manual it was fairly easy. I did not take out my injectors or disconnect my throttle cable as the manual suggested. I did unplug the electrical connectors to them to remove the intake manifold so I could clean the gasket surface on the head.
I agree going with a quality replacement header. It's a job you don't want to do twice.

PS. spray all the bolts with WD40 or .... several times a few days prior you will thank yourself.
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