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Unread 06-19-2009, 06:04 PM   #1
klr85
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2001 TJ Wrangler 
 
Join Date: Apr 2004
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Exhaust nightmare

I had to replace the y-pipe with the 2 cats. to pass inspection. After installing the new pipe I can not get to pipe to seat right on the manifold. It's a 2001 4.0L, I checked with jeep and there is no gasket that goes in between. I have spent about 18 hrs. on this and can not fix it. Any and all help would be great.
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Unread 06-19-2009, 06:36 PM   #2
06WranglerX
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How does it sit when you try and get it on, does it sit slightly cocked, or does it not even come close to the mating surface? Also where in jersey I might be able to assist if you need an extra hand as I am in northwest jersey. Also got any pics of the issue?
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Unread 06-19-2009, 06:52 PM   #3
klr85
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It sits slightly cocked. No matter how many times I take it apart the same thing happens. It will sound O.K. but when I start to drive it gets loud again. I'm in Fords, NJ & I have even brought it to 2 shops with no luck.
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Unread 06-19-2009, 07:04 PM   #4
Jasen
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Have you tried a bead of RTV silicone as a gasket. Let it sit untill completly cured, about 24 hrs. then re install your manifold.
Been her done this a few times with headers on hot rods.
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Unread 06-19-2009, 07:07 PM   #5
klr85
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I thought about that and the 2shops I went to wouldn't do it and jeep also said not to put anything there. I'm about to just pay the dealer to redo the whole job, parts and all
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Unread 06-19-2009, 07:44 PM   #6
Jasen
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I'm sure the 2 shops and the dealer said not to because it's not a propper application in their repair book minds. Never mind the fact the MFGrs have been omitting gaskets for years now and using RTV instead.
The RTV can't hurt anything, and at worse, it will just fail. If nothing else, it's an inexpensive fix and your only out $4 if it fails. The big concern would be having a leak over a long period of time and pitting the mating surface of the head.
That is infact one of the times I used RTV on a header. A gasket just couldn't seal up the pitting.

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Unread 06-19-2009, 08:50 PM   #7
GOLENJEEPTJ
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Leave the exhaust flange at rear cat loose.Do not tighten up the three nuts there.At the Y your going to have to tighten the 4 nuts and bolts evenly on each individual flange. I always look through driverside fender well to see if I have them lined up even.You don't need RTV,you need too get the bolts squared up evenly.RTV isn't going to do squat if uneven.Take your time.It's a pain I know...but doable. Good luck!p.s. On my long arm I drop the front driveshaft it makes for a heck of a lot more room. I doubt you have this scenario?
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Unread 06-24-2009, 05:33 PM   #8
klr85
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I still have had no luck. One shop told me that the part I ordered is belt wrong and no matter what they had tried no luck. Would wrapping Foiltape round the void work or would it burn up from thee heat?
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