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

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
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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.
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[@offgridcowabunga3729]

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]

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]

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

[@dg98adams]

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

[@FlawedOffroad]

Anymore EVERY job turns into a bigger job😅

[@sinisternm]

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

[@FlawedOffroad]

it definitely under performed lol

[@danielhixson3717]

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

[@tsmith578]

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]

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

[@SimplyMustGo]

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]

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

[@TheBandit7613]

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]

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

[@TheBandit7613]

@@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.

[@davidjenkins4838]

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]

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

[@brian4579]

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

[@FlawedOffroad]

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]

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

[@FlawedOffroad]

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

[@DaddyJeepGarage]

Why does the cracked manifold say DAN?🤣😂

[@FlawedOffroad]

Been waiting for someone to catch that haha

[@Motoman714.]

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]

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

[@brianmegill2230]

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]

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

[@mattluszczak8095]

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

[@FlawedOffroad]

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

[@Halfdaf]

If you go back and buy the chinese intake manifold will they match up? lol

[@FlawedOffroad]

Dont think they sell one lol.

[@jeepdoctv]

Dang Chineseum junk!!