Jeep Exhaust Manifold Won't Seal? Watch this!

Jeep Exhaust Manifold Won't Seal? Watch this! - 2.5L 4.0L YJ TJ XJ

Рет қаралды 5,409

Жыл бұрын

Took on a job to replace an exhaust manifold on a 99 TJ wrangler 2.5L and of course the cheap casting was way too thick which did not allow the intake to seal up. So its time to get creative...
The process is the same on a 2.5 or 4.0 just add a few bolt locations to the mix
Tools I used:
Stripper Discs- amzn.to/3pxLNN9
Carbide bits- amzn.to/3wIKiQf
Air die Grinder- amzn.to/3wm1URt
Electric ratchet- amzn.to/3wn6Fdz
🔥Partner Discounts🔥
Use my code: Flawedoffroad
To save 10% at the following companies!
--------------------------------------
⚡YESWELDER⚡ yeswelder.com/?ref=Flawedoffroad
🌟Yankum Ropes🌟 5% yankum.com/?afmc=Flawedoffroad
🔦Auxbeam🔦 12% Code: FLDORD
☕TRAIL RATED COFFEE☕ bit.ly/3IAF1xR
Great coffee that donates to Trail preservation!
--------------------------------------------------(affiliate links)--------------------------------------------
Follow me on Social media:
Instagram - / flawed_offroad
linktr.ee/Flawed_offroad
revkit.com/hell-on-wheels
#jeepyj #jeepTJ #jeeprepair #yj
Disclaimer:
Due to factors beyond the control of Flawed Offroad, I cannot guarantee against improper use or unauthorized modifications of this information. Flawed Offroad assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Flawed Offroad recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Flawed Offroad, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Flawed Offroad.
This video and description has affiliate link(s), which means that if you make a purchase after clicking one of the links, I’ll receive a small commission. Which helps me continue to make more content.

Пікірлер: 32

@offgridcowabunga3729 Жыл бұрын

Brrrrooooooo.....I could hug u while jumping up and down!! 1st wrangler I've ever owned... exhaust manifold cracked in half. Replaced it with a Amazon cheapo. High idle and bucking all over. Replaced the gasket and flipped it thinking I had it wrong...still high idle. New iac, tps , coolant sensor, cleaned tb, fixed any bare wires and new O2. Lil better but still high idle and revving when I'd tap on tb. No leaks found with carb clean and no codes. About to push it off a cliff...watched ur video after 1000 I've already watched...went out with a flashlight and climbed up and Sure as hell... Washers angled. / . Tomorrow I'll buzz em down and see. 🤞🏻Tks for the awesome video.

@FlawedOffroad Жыл бұрын

This right here is exactly why I take the time to make videos. Makes my day when they save peoples bacon. Glad it helped and I bet it will fix it, good luck!

@offgridcowabunga3729 Жыл бұрын

@@FlawedOffroad definitely fixed it. Took a few grindings to get it right but goes on and off easy after 5 times 🤣🤦🏻. Mahalos 🤙🏻

@danielhixson3717 12 күн бұрын

The man is not kidding about these Chinese manifolds and headers. I have not found one yet where at least one hole is misaligned.

@sinisternm Жыл бұрын

this should have a million views..... thanks man. same boat club

@FlawedOffroad Жыл бұрын

it definitely under performed lol

@dg98adams Жыл бұрын

Every job can turn into a bigger job, but good job on the “fix”

@FlawedOffroad Жыл бұрын

Anymore EVERY job turns into a bigger job😅

@SimplyMustGo Жыл бұрын

Why is it that nothing is ever as easy as it should be and why don't replacement parts ever fit the way they should... UGH! Great job though!

@FlawedOffroad Жыл бұрын

Youre tellin me lol. I wish I would have noticed it before fully assembling the Jeep!

@davidjenkins4838 2 ай бұрын

No, it’s the correct thickness. You need the OEM half washers on the shared intake/exhaust bolts. All bolts should have a conical washer as well.

@FlawedOffroad 2 ай бұрын

the one I took off was OEM, there were no half washers and it was the same thickness as the intake. I think you just had one that someone modified

@tsmith578 Жыл бұрын

I had the same issue with the header flange being too thin on the Spec D brand header I bought for my jeep 4.0 litre ZJ. The flange was 3/8" thick instead of 1/2" thick like the original one. So to remedy that I used 4 3/8" diameter grade 8 washers and cut them in half, and then welded them to the header flange that has the bolts that are shared with the intake manifold. And instead of the cheap metric grade 8.8, 10mm diameter bolts that came with the header, I used a pair of 7/16" diameter grade 8. X 2" long bolts and with grade 8 nuts and lock washers for the connection from the header to the lead pipe. And it worked out great and solved all the leaks that were by the engine.

@FlawedOffroad Жыл бұрын

I once had the same problem with the speed daddy header being too thin

@TheBandit7613 Жыл бұрын

I have a 92 YJ Sahara. Of course I had a cracked exhaust manifold. I took it to local machine shop because I figured the cheap thing wasn't going to be flat. So I just asked them to machine it to where it's flat. It worked perfect. I guess I just got lucky. I also had that machine the intake manifold while it was off. I figured it might be warped from 30 years of hot cold.

@FlawedOffroad Жыл бұрын

suppose that would help, sounds pricy. usually they are cracked more so than warped

@TheBandit7613 Жыл бұрын

@@FlawedOffroad Yes, a little of both! I had a vacuum leak (CJ7 258) Pulled it apart, yes, a hairline crack, intake manifold. Got a used intake manifold. Still a vacuum leak. Pulled apart. The intake manifold was warped a bit when checked with a strait edge. Took it in, had it machined. PERFECT. No leaks. Then, my YJ (I have two Jeeps) Exhaust cracked. Pulled apart, new exhaust manifold with bellows. And the intake manifold had a vacuum leak. Damn! Turns our, the new exhaust manifold was not perfect and my intake manifold was not perfect. Had them both machined... perfect. No leaks. Yes, expensive but I HATE leaks and vacuum leaks are so common. From now on, anything that comes apart, gets machined.

@brian4579 2 ай бұрын

I wish there was a proper replacement part available for purchase. It’s frustrating not having oem spec parts at the ready.

@FlawedOffroad 2 ай бұрын

I mean they fit other than that thickness issue, I had a couple people try to tell me the OEM ones were like that too and they came with offset washers that are thicker on one side than the other but I think that’s a load of crap. Good luck modifying

@raleighanderson1124 2 ай бұрын

Instead of grinding it down, could you put some type of piece of metal between the washer to flatten it out?

@FlawedOffroad 2 ай бұрын

I’ve heard rumors of some offset washers that are thicker on one side than the other but I’ve never seen them

@Motoman714. Жыл бұрын

I have a 98 xj with a motor from a supposedly 98 xj from a junk yard so i put a header from JEGs on it but I’ve tried 3 different headers and they have all leaked i have the one that came with it but i don’t trust it. Im gunna check for warped ex. Side

@FlawedOffroad Жыл бұрын

Did you make Sure to get the 2 alignment studs fully seated? I’ve seen that cause people a lot of grief

@DaddyJeepGarage Жыл бұрын

Why does the cracked manifold say DAN?🤣😂

@FlawedOffroad Жыл бұрын

Been waiting for someone to catch that haha

@mattluszczak8095 Жыл бұрын

How did the welding go.? Normal mig wire or some special wire?

@FlawedOffroad Жыл бұрын

I used normal mig, just a little bit of preheat and I peened the weld and wrapped it in a weld blanket after to cool slowly since its cast. YOu can also use a stick welder with nickel rods, that actually works better on cast if you know what ur doing

@brianmegill2230 17 күн бұрын

Dumb question - the original manifold didnt have a 2nd hole in it like the one you installed - what is that other hole for? Does anything need to plug into that or does that just stay open?

@FlawedOffroad 17 күн бұрын

@@brianmegill2230 probably another o2 sensor for newer engines or something. It came with a plug and a copper washer to plug it