Cracked Exhaust Manifold

Jeff41 · 03-03-2003, 09:11 AM

I have a 98 sport 6 cyl and the Exhaust Manifold has a crack - has anybody else had this problem and or suggestions for repairs other than taking it to the dealer?

97TJ2.5 · 03-03-2003, 09:33 AM

this may be one of the only things worthy of a dealer fix. I believe that there is an extention on the emissions warranty that will replace your manifold/header for free... I have heard that it is worthwhile because the factory header is comperable to an aftermarket header anyway...

if you have less than 80k on your motor, it should be free...

gtflyer · 03-03-2003, 09:36 AM

If you can get the dealer to fix it under warranty go that route,but otherwise ..time for a header replacement!..Go with a stainless one that has a lifetime warranty on it like the Banks header or similar..that way you will not need to worry about it again!

cptn_mrgn78 · 03-03-2003, 10:43 AM

Can anybody comfirm the 80,000 mile warranty on stock manifold/headers? I know there is a 80,000 mile warranty for the catalytic converters.

97TJ2.5 · 03-03-2003, 11:01 AM

the manifold system is included in the "emissions" warranty extention. I have a 97TJ with a 4cyl. They did it for free....

they run your vin to see if your vehicle is covered....

cptn_mrgn78 · 03-04-2003, 10:11 AM

Thanks. I just wanted to be sure.

98JPTJ · 03-05-2003, 02:16 PM

You guys got me all excited talking abou the emissions warranty extension up to 80,000 miles, but I called the dealer and he said that was only for the four bangers. I have a six. Myself and some fellow six cylinder buddies have experienced cracked manifolds on the 4.0L anybody else experience this?

gtflyer · 03-05-2003, 02:57 PM

99JPTJ- all the Jeep manifolds crack!...Period!..If the dealer will not help you it is is time for a header replacement..Go with a stainless replacement like i said before and then be done with it!..I personally am partial to the banks header and so are many of the guys over at jeepsunlimited who have gotten them...just a word of advise:if you replace it with a mild steel replacement ,it is going to crack again and you will end up paying more $$ in the long run...good luck

jeep4fishing · 03-05-2003, 03:21 PM

Cracked manifolds have plagued the 4.0 inline six from the begining. If I had been on this forum 5 years ago when mine was discovered I'd have upgraded, but I just had the dealer fix it with a direct replacement. (stupid me, I paid for it too) I agree about upgrading, it would probably cost less for after market parts than the dealer would charge for the direct replacement.

98JPTJ · 03-05-2003, 03:33 PM

Actually I have been able to weld my manifold up. i was just complaining in general about defective factory parts

**Jerry Bransford** · 03-05-2003, 03:49 PM

Quote:

Originally posted by gtflyer
99JPTJ- all the Jeep manifolds crack!...Period!..

No they don't, at least not since around mid-1999 model year. First of all, it's a header and not a manifold. The header was redesigned in 1999 with a pair of flexible steel bellow joints at the point where the cracks were happening as a result of engine torque twisting the headers around. Since the new design has been shipping, I know of no one with the new version that has had a cracked exhaust header. I went through 3 of the original design headers with all of them cracking before my '97 TJ was out of warranty. Then around 75,000 miles ago, I got the new crack-proof header installed and it's been fine ever since.

gtflyer · 03-05-2003, 05:25 PM

that is funny..I have 3 member in my club (a late 99,01 & 02) and CRACK!!!!...OK..it is a header with the bellows,but to me it is just a step up from the old JUNK they used to install..Now instead of cracking at the collector or flange welds,they crack at the point where the primary tubes meet at the straight point off of the 1st tube..When you can get a replacement for those on Ebay for $200 all day long,there is obviously a problem there as well.

Bow Hunter tj · 03-05-2003, 06:10 PM

I have the header with the bellows and your right they are crack proof. The problem is the rest of the header is not!!!! Mine has cracked in three different places.... But the bellows is still intact!!!

Great New Design!!!

**Jerry Bransford** · 03-05-2003, 07:14 PM

Quote:

Originally posted by Bow Hunter tj
I have the header with the bellows and your right they are crack proof. The problem is the rest of the header is not!!!! Mine has cracked in three different places.... But the bellows is still intact!!!

Great New Design!!!

I stand corrected then. But in 3-4 years, these are the only reports I've seen of the new design cracking. I know mine has held up fine since being installed around almost four years ago.

gtflyer · 03-05-2003, 09:56 PM

Glad to see you have been lucky with yours Jerry,but there are alot of headers being made and shipped weather it be by Banks ,Borla or whoever to replace the factory ones..And not everybody is replacing them for performance only reasons..I give it a:May not crack as quick,but it is still bound to happen..