Installing new Exhaust Manifold on 4.0 TJ.......How Hard?

[ad5at]

Iwould like to install one of those new exhaust manifolds for 4.0 ltrs. that have the expansion joints in them that will help to alleviate the cracking problem. I have been putting up with a cracked manifold for some time.

How difficult of a job is this? Looks as if though you need to remove the power steering pump, intake manifold, fuel rail, possibly the front driveshaft? Are there any specialty tools required for any of these parts for remove and install?

I know that someone on here has surely done this. PLEASE respond.

Thanks!

P.S......Jeep knows that there is a problem with these. I wish that Chrysler would just redesign the darn thing!

 

[jps4jeep]

not fun! at least on the YJ's you need to pull the entire intake manifold off to access some of the bolts.

Not a hard thing to do, just tedious!

 

[flyboy]

coil spacers

I did mine on my 99 TJ and it wasn't "that" bad. The manifold and the intake are held on by the same bolts. No special tools were required. I do remember having to move the power steering pump out of the way but you don't need to disconect it fully. I did mine in January at -20 C and it only took me about 3.5 hours. (had to stop to defrost a couple of times) One thing to remember is to make sure you torque the bolts properly when you put them back on and replace the gasket at the same time.

 

[jeepdude832]

I did mine last year same thing a 99. You dont hve to disco all the intake manifold stuff just set it up on the side and drop your drive shaftand go down that way. Make sure you seal the gasket very well I had a small leak that put my engine up th 4000 rpm had to do over use the "right stuff " gasket material no probs after

 

[redrooster]

00XJ O2 Sensor Question

Time consuming but not too hard. I had to do this repair on my 93 Grand a few years ago. I didn't replace the manifold, just had it welded up.

 

[ad5at]

Thanks everyone. Much appreciated!

 

[dick_wilderness]

I'd like to try it myself.

 

[JDKing]

I did it last year on my 91 YJ it does take a bit of time but over all well worth it, my front drive shaft does hit the side of the header on occasion, but thats when i doing alot of bouncing in the mud. if it does wear through i will heat up the manifold with a torch and bend it where its out of the way, and patch it up with a little heavier steel.

I bought mine out of JC Whitney along with the gibson exhaust, new cat and all welded up to ensure no leaks, and i love the way it sounds.


JK

 

[Joopin]

I did it last year on my 91 YJ it does take a bit of time but over all well worth it, my front drive shaft does hit the side of the header on occasion, but thats when i doing alot of bouncing in the mud. if it does wear through i will heat up the manifold with a torch and bend it where its out of the way, and patch it up with a little heavier steel.

I bought mine out of JC Whitney along with the gibson exhaust, new cat and all welded up to ensure no leaks, and i love the way it sounds.


JK

Hey JDKing, I also have a 91 YJ and I'm curious what header you bought for yours. I have been shopping around for a while now, but in the mean time my exhaust is getting worse by the second.

Joop

 

[JDKing]

i bought the gibson out of JC Whitney. my old header didnt have the knuckles and was cracked thruogh on 3 of the header tubes...