Cracked exhaust header

[gixer]

Ok so on my 97 XJ the exhaust cracked. Go figure. What can I do to kind of quiet it down some or seal it some. I have not found any thing useful in a search so far.
Any one use header wrap ????
It says it’s good to 2000 degrees.
I just want to put a band aid on it for now.
JB weld and some permatex steel stuff did not work at all.

[Harlee&Tahoe]

muffler mender? I'm having the same problem. that is what I'm going to try on my 87.

[jeepdude10000]

after u put muffler mender on or what else u put on, put over top some header tape, it will last longer.

[gixer]

I just used muffler mender and it lasted 10 min.
I dont think the tape would help much.

[BIGSLVRXJ]

What can I do to kind of quiet it down some or seal it some.
You're gonna have to replace it. There really is no "band-aid" for it. You could take it off, and weld the crack shut, but it'll leak again in a month.

[gixer]

You're gonna have to replace it. There really is no "band-aid" for it. You could take it off, and weld the crack shut, but it'll leak again in a month.


I have one on order just wanted to do some thing in the mean time.

[BIGSLVRXJ]

I have one on order just wanted to do some thing in the mean time.
You go with the one from APN?

[gixer]

You go with the one from APN?


yeah

[BIGSLVRXJ]

yeah
:thumbup: I just put mine on about a week ago. I haven't actually fired my engine up yet because I've been waiting on other parts but as far as the look and feel of it, its gonna be a winner.

[mrbill3]

yeah

I put the one from APN on mine a few moths ago and it was a piece of cake. Took about an hour and man is it quiet now! It also made it run alot smoother. Bye the way, where on Long Island are you from? I'm originally from East Islip, but now live on the central coast of California just outside of Pebble Beach.

[gixer]

I put the one from APN on mine a few moths ago and it was a piece of cake. Took about an hour and man is it quiet now! It also made it run alot smoother. Bye the way, where on Long Island are you from? I'm originally from East Islip, but now live on the central coast of California just outside of Pebble Beach.

I used to live in East Meadow and then Farmingdale.
I am Now in Virginia.

[jeepdude10000]

I put the one from APN on mine a few moths ago and it was a piece of cake. Took about an hour and man is it quiet now! It also made it run alot smoother. Bye the way, where on Long Island are you from? I'm originally from East Islip, but now live on the central coast of California just outside of Pebble Beach.

I was told u had to take off the intake also, is this true?

[gixer]

I was told u had to take off the intake also, is this true?

Yes

[mrbill3]

I used to live in East Meadow and then Farmingdale.
I am Now in Virginia. Ahh, another misplaced New Yorker!!



I was told u had to take off the intake also, is this true?
Yes. You need to remove the intake as well as the exhaust manifold in order to replace the gasket. It isn't as difficult as it looks, it's just hard to reach some of the bolts underneath. When you put it back together be sure to put the exhaust manifold on before the intake. It will help hold the gasket in place and also free you up to use both hands. Good Luck!!!

[reliablestv]

did you try to weld the crack?

[gixer]

did you try to weld the crack?

I was going to but every one was saying it would not last and would end up larger than before.

[mdicanio]

The pipe on mine recently cracked. On mine it is down where the two pipes meet at the bottom just before the where the header connects to the rest of the exhaust.

If I don't fix this, what is the worst that will happen? Will the pipe completely separate and make things real loud?

[jdougn]

The pipe on mine recently cracked. On mine it is down where the two pipes meet at the bottom just before the where the header connects to the rest of the exhaust.

If I don't fix this, what is the worst that will happen? Will the pipe completely separate and make things real loud?


Mine ran cracked for a long time, as in a couple years. I believe it caused the engine to run hot and it ended up melting the rubber on the engine mount. I got the replacment from APN and have been satisfied so far.
dn

[mdicanio]

That's what I was thinking. Do you have any idea what causes this? I was thinking it is the motor mounts are weak allowing the motor to flex more than it should.

[96CheroKeeClassik]

my check engine light kept coming on in my 96, and it was the oxygen sensors.......replaced them, still had them problem. Turns out I had a cracked manifold. I had it welded and it has been fine over the last six months with the occasional check engine light....

[Blaine B.]

How about Marine-Tex or high-temp JB weld?

I heard success stories with both as long as you clean the surface well before applying the compounds.

By the way, I have a hairline crack on mine where the 2 header pipes converge into one, right before the junction where it connects to the rest of the exhaust. This may be causing me to run rich which would be a reason for my lower than average MPG with a stock XJ.

[falcon556]

my check engine light kept coming on in my 96, and it was the oxygen sensors.......replaced them, still had them problem. Turns out I had a cracked manifold. I had it welded and it has been fine over the last six months with the occasional check engine light....

Had my 96 welded 3 months ago, holding up well.
I understand there is a class action suit going on regarding this problem.

[Blaine B.]

Oh so perhaps no forms of patching/welding should be attempted until the verdict of the suit is discovered?

Maybe they would then say it wasn't covered becuase you tried to modify it, etc. etc.?

[falcon556]

Oh so perhaps no forms of patching/welding should be attempted until the verdict of the suit is discovered?

Maybe they would then say it wasn't covered becuase you tried to modify it, etc. etc.?

Normally a class action suit gets you a few bucks and millions for the lawyers and it doesn't matter what you do.
Just a way for lawyers to rip off companies.
My concern was to fix my Jeep. While looking for exhaust manifolds I ran into the lawsuit info. Given a choice, I won't participate.

[Blaine B.]

Oh, I was perhaps thinking it would be recalled and replaced free of charge, just like the fan speed plug behind the climate controls.

[falcon556]

Oh, I was perhaps thinking it would be recalled and replaced free of charge, just like the fan speed plug behind the climate controls.

That would be nice, everybody I know with a 4.0 had this problem, including myself three times.

[bajacalal]

That would be nice, everybody I know with a 4.0 had this problem, including myself three times.

Exactly, this isin't something that should happen to a car with less than 100,000 miles on it. And it happens to every 4.0 I see with the old style manifold.

[falcon556]

Exactly, this isin't something that should happen to a car with less than 100,000 miles on it. And it happens to every 4.0 I see with the old style manifold.

It is not normal, no question about it.
Too bad Chrysler won't do something about it.

[brianb2247]

take it off and take it to a exhaust shop and have them weld the cracks

[outlander]

I think the problem lies in the way the exhaust headpipe is mounted on these jeeps.I'm looking into adding a flex joint in mine to lessen fatigue.....

[mdicanio]

It is not normal, no question about it.
Too bad Chrysler won't do something about it.

Does it happen to the 4.0 in the Grand Cherokees also? I know the 4.0 is used in the Grand up until 2004?

[falcon556]

Does it happen to the 4.0 in the Grand Cherokees also? I know the 4.0 is used in the Grand up until 2004?

I have a WJ 01 with the 4.0, about 90K no problem, this is my first WJ, the wife drives it and I don't spend nearly as much time with it as I do with the XJs.

[Nixt]

The class action lawsuit mentioned earlier in this thread is at:
http://www.gtelaw.com/jeepclassaction/

[Blaine B.]

Thanks, I can't wait to get my 50 cent! lol:lickout:

[gixer]

Yeah
The lawers are the only ones going to get any thing from it.
Its been going on for a long time also and there are a few of those web sites around.

[RBNRaider]

Only way you can fix a cracked header is welding the crack (Firepower makes great cast iron electrodes for arc welders) A less expensive quick fil is JB Welds metal filler which I have actually used to retap engine bolts and also fix cracked headers.

[falcon556]

Only way you can fix a cracked header is welding the crack (Firepower makes great cast iron electrodes for arc welders) A less expensive quick fil is JB Welds metal filler which I have actually used to retap engine bolts and also fix cracked headers.

Some members report bad luck with welded headers, I had two welded.
a 1987 that kept for another 2-3 years after the welding and a 96 that I did recently. The first worked great for as long as I kept it, so far so good but too early to tell for the 96.

[bacelaw]

Just a way for lawyers to rip off companies.


so when huge classes of people have valid claims/damages from the negligence of a large company.......we should do what?

lawyers are not in the business of "ripping off companies," no offense, but what an ignorant thing to stay.

[1996cc]

lawyers are not in the business of "ripping off companies," no offense, but what an ignorant thing to stay.

I think you just displayed your own ignorance. Lawyers earned their reputation.

[falcon556]

so when huge classes of people have valid claims/damages from the negligence of a large company.......we should do what?

lawyers are not in the business of "ripping off companies," no offense, but what an ignorant thing to stay.

I get a letter informing me that I am a part of a class action suit, whether I like it or not. The case goes through they send me Kodak film (polaroid) or coupons or in one case $15 that covers nothing.
In the mean time the lawyers get millions, or in the case of the tobacco companies that never explained to me that smoking is bad for me, billions and I the smoker, nothing.
I don't know what you call it, at the end we all pay for it.
BTW one reason that we have no progress in so many industries (General Aviation is a prime example), is the fear of law suites. When you get your next flu shot, it will be made overseas for the same reason.
As far as I am concerned they can go to hell.

[bacelaw]

I get a letter informing me that I am a part of a class action suit, whether I like it or not. The case goes through they send me Kodak film (polaroid) or coupons or in one case $15 that covers nothing.
In the mean time the lawyers get millions,

....ok, and the company that was negligent pays through the teeth - it is our way of punishing people who do something wrong...something wrong that is not necessarily illegal.

or in the case of the tobacco companies that never explained to me that smoking is bad for me, billions and I the smoker, nothing.

no one ever explained to you that smoking was bad for you? so you should receive millions?


I don't know what you call it, at the end we all pay for it.
BTW one reason that we have no progress in so many industries (General Aviation is a prime example), is the fear of law suites. When you get your next flu shot, it will be made overseas for the same reason.
As far as I am concerned they can go to hell.

Law "suites"...all lawyers should go to hell - then the world would be a progressive and industrious place. lawyers are the reason that general aviation technology has not progressed quickly enough for you. what a joke - i dont even have to honor these bogus, incoherent statements with an argument.

What do you think - lawyers should work for free? I would like to hear what your alternative method of dispute resolution is, who pays for it, and what low-pay professionals will implement it.

Sure there are lawyers who deserve their poor reputation - as in any profession. But the next time you are in legal trouble, have a legal issue that demands your attention - reread your comments about lawyers. The profession is completely necessary - and as a whole your characterization of lawyers as scum is completely unfounded.

The common misconception of the ambulance-chasing and morally relaxed attorney is a result of the media, television, and movies.....why dont you turn your television off, your brain on, and form an opinion of your own.

[falcon556]

....ok, and the company that was negligent pays through the teeth - it is our way of punishing people who do something wrong...something wrong that is not necessarily illegal.

We punish people by enriching the lawyers. COOL!


no one ever explained to you that smoking was bad for you? so you should receive millions?

I never asked for any, never received any, got stuck paying.
The smoker was the supposedly injured party for whom it was done for, the lwayers got the loot.

The common misconception of the ambulance-chasing and morally relaxed attorney is a result of the media, television, and movies.....why dont you turn your television off, your brain on, and form an opinion of your own.

I wonder what kind of person could look at the current system and think it is working as it should. You need to do some reading, start with John Stossel's latest book. Who knows, you might learn something.

[bacelaw]

We punish people by enriching the lawyers. COOL!




I never asked for any, never received any, got stuck paying.
The smoker was the supposedly injured party for whom it was done for, the lwayers got the loot.



I wonder what kind of person could look at the current system and think it is working as it should. You need to do some reading, start with John Stossel's latest book. Who knows, you might learn something.
Thanks for the education - guess law school didn't teach me much of anything.

Where did you get your law degree? your p.h.d i guess it must be?

Heres your free education: We punish civil wrongs by making the wrongdoers pay money...we make the wrongdoers pay those who they injur or damage - amounts of may be awarded either by settlement (before trial) or juries (through trial).

Lawyers, like doctors, as professionals charge a fee for their services. In personal injury suits, it is generally 30% of whatever damages are awarded, or agreed to via settlement.

You are very critical of "the system," and it seems as though you have it all figured out - so here's a simple question: can you offer a more efficient and less costly system of dispute resolution?

What is your magical intelligent plan to solve the horrible effects that lawyers have had on our moral society?

So when someone close to you is injured horribly, or god fobid dies as a result of a doctor's gross negligence - how should we solve that problem without lawyers?

If you have a contract with someone and they simple tell you to pound sand when it's time for you to pay - you are NOT going to call a lawyer? How do you propose those situations should be handled?

You are so wise, please, enlighten me. Give me the education you said I required due to my ignorance in believing that the civil legal system, although not perfect, is best served by professional, skilled, educated, and ACCOUNTABLE advocates.....Lawyers.

[falcon556]

Thanks for the education - guess law school didn't teach me much of anything.

Where did you get your law degree? your p.h.d i guess it must be?


A lawyer, I would've never guessed!
I am a Roads Scholar and you are a very impartial debater. :D

[bacelaw]

A lawyer, I would've never guessed!
I am a Roads Scholar and you are a very impartial debater. :D

Great response to my simple questions. You were so fired up and quick to disparage the "system" and lawyers in general.But, when asked simple questions, you resort to a stupid joke.

Before you insult an entire profession, be prepared to defend your opinion.

This is especially good advice if the professionals you are insulting are trained to argue, spend $100,000+ on their education, three years of grueling testing, a miserable bar examination - and then spend the rest of their extremely busy lives attempting to perfect their professional abilities. This is also a profession that can claim more than half of all U.S. Presidents as their colleagues.

(and it's Rhodes Scholar)....my work is done here - consider yourself skewered!!!

:hang:

[falcon556]

Great response to my simple questions. You were so fired up and quick to disparage the "system" and lawyers in general.But, when asked simple questions, you resort to a stupid joke.

Before you insult an entire profession, be prepared to defend your opinion.

This is especially good advice if the professionals you are insulting are trained to argue, spend $100,000+ on their education, three years of grueling testing, a miserable bar examination - and then spend the rest of their extremely busy lives attempting to perfect their professional abilities. This is also a profession that can claim more than half of all U.S. Presidents as their colleagues.

(and it's Rhodes Scholar)....my work is done here - consider yourself skewered!!!

:hang:

Your education didn't get you far enough to recognize a joke.
Roads Scholar, like life experience, got it?
BTW if you knew anything about General Aviation, you would have known that we had something beautiful that was destroyed by people claiming to be there to help others, using their 100,000+ education to enrich themselves.
I do agree with you on one point, this has gone far enough.
Good Day.

[bacelaw]

Your education didn't get you far enough to recognize a joke.
Roads Scholar, like life experience, got it?
BTW if you knew anything about General Aviation, you would have known that we had something beautiful that was destroyed by people claiming to be there to help others, using their 100,000+ education to enrich themselves.
I do agree with you on one point, this has gone far enough.
Good Day.

Apology Accepted.

:farmer:

[eric91xj]

damn i have'nt been on here in a long time, anyhow back when i had my '91 Xj i made a successful patch that lasted a couple years using this stuff i got from a hardware store, some sort of 1/2 epoxy, 1/2 cement, 1/2 jb weld looking stuff i think it was called furnace cement, not 100% sure but i think thats what it was, just globbed it on and it worked pretty dang good for a long time.

[1996cc]

Apology Accepted.

:farmer:

Someone's ego is a little big for his own britches!!

[Blaine B.]

so when huge classes of people have valid claims/damages from the negligence of a large company.......we should do what?

lawyers are not in the business of "ripping off companies," no offense, but what an ignorant thing to stay.

The hell they aren't!:anon:

[POSXJGuy]

hello folks, i also installed the much debated APN header about a month ago and its been doing well. I had to do a tiny bit of grinding on the intake and the header to get em to mesh right but in all it was an easy job. it was hot and i was sweatin like a pig in my garage but it was all good. i left injectors on and did not mess with the rail. marked everything real well and then just proceeded to cuss at the manifold bolts with every type of adapter imaginable. of the whole install the most brain whacking part was trying to get the bottom two bolts towards the firewall back on the damn block. after everything is on and re-connected it was smooth sailing from there.

no more exhaust leak and performance wise i don't give a hoot as long as the stupid exhaust leak is gone. sounded like a goped before i fixed it.

i used the permatex copper spray on the gasket while assembling.

so i have put about 2k miles on the apn header now and its ok, nothing weird about it and looks like its doing the job. i dont have a lot of mechanical experience but it was not too hard. just mark everything and take the time to clean the parts while your at it.

[falcon556]

i used the permatex copper spray on the gasket while assembling.


Never used it, is it a requirement?

[UNCC_99XJ]

my check engine light kept coming on in my 96, and it was the oxygen sensors.......replaced them, still had them problem. Turns out I had a cracked manifold. I had it welded and it has been fine over the last six months with the occasional check engine light....

I've been having the CEL come on randomly since march. It keeps throwing P0138 for the o2 sensor #2 shorting out. Is this what yours was doing? My exhaust doesn't really sound too abnormal, but then again i do have a flowmaster on it so it can be hard to tell. mpg has been a steady 17-19 all city with the a/c on, and I havent really noticed any rough running, with the exception of sometimes with the a/c on and the first time i stop once the engine has warmed up. With the a/c if i get on the gas pedal moderate to heavy and let back off real quick, rpm's drop and it tries to stall, but the compressor kicks off and the engine recovers, and then the compressor kicks back on and all is good. With the stopping after warm up, the rpm's dip down a little bit, but it quickly recovers.

[Blaine B.]

17-19 in city????? I get less than 14!

[falcon556]

I've been having the CEL come on randomly since march. It keeps throwing P0138 for the o2 sensor #2 shorting out. Is this what yours was doing? My exhaust doesn't really sound too abnormal, but then again i do have a flowmaster on it so it can be hard to tell. mpg has been a steady 17-19 all city with the a/c on, and I havent really noticed any rough running, with the exception of sometimes with the a/c on and the first time i stop once the engine has warmed up. With the a/c if i get on the gas pedal moderate to heavy and let back off real quick, rpm's drop and it tries to stall, but the compressor kicks off and the engine recovers, and then the compressor kicks back on and all is good. With the stopping after warm up, the rpm's dip down a little bit, but it quickly recovers.

I've been told that a cracked exhaust can suck in air as it pulses, altering the exhaust mixture and making it appear too lean to the sensor. In turn the puter tries to make it "right" by enriching the mixture, creating a mess.
I also have a 99 with an intermittent sensor light, I had the driver get it checked at Autozone but failed to write down the details. It came and went a couple of times and I decided to ignore it.
I had a similar experience with a Maxima, high heater resistance caused a fault. The resistance was just a little outside the standard value. Left it alone, the light went out, came back a couple of times and then stayed out permanently.

[POSXJGuy]

Never used it, is it a requirement?

hey falcon, i dont think its a requirement but i read somewhere that it can't hurt. its weird though, you buy a big ol can of it and you only use a few squirts.

i had a yota a while back and when i did those headers with no spray the result was the same, fine either way. i guess those wires and hoses above the intake got me a bit paranoid about having to disassemble so i thought i would do it in case it helps.

either way, i think it will work with or without that "copper spray".

[falcon556]

hey falcon, i dont think its a requirement but i read somewhere that it can't hurt. its weird though, you buy a big ol can of it and you only use a few squirts.

i had a yota a while back and when i did those headers with no spray the result was the same, fine either way. i guess those wires and hoses above the intake got me a bit paranoid about having to disassemble so i thought i would do it in case it helps.

either way, i think it will work with or without that "copper spray".

I use Hy Tack on waterpump gaskets, never thought about using anything on exhaust gaskets.

[boise49ers]

Apology Accepted.

:farmer:


Boston Legal :laugh3:

[blacksheepxj]

In the posts people are mentioning APN headers for the XJ's. I have never heard of these before. I have looked into the Banks and Pacesetter ones. I have a 96 and have welded the header twice. I was going to buy the Banks one but by thime I have it shipped to the east coast of Canada it was going to cost me almost $700.

Rob

[falcon1235]

GO GO thread hi-jackers :sure:

[boise49ers]

GO GO thread hi-jackers :sure:
8 Posts and that is one of them ? :sure:
I just took my Rig to the muffler shop and he said he can weld it with pretty good results , but of course no warranty, which was expected. I have to take it off because it is on the block side. It is a RE Stainless steel. The crack is about 2" long and very small. Almost heals itself when it is hot.
I really don't want to have to pull off all that crap for such a little crack unless I have to. So what is the best compound you guys who have had desent results with ? I would think cleaning and roughing up the surface is the key to good results. My crack is where one tube hooks onto the collection pipe at the weld. Very small.
Falcon this one isn't a hi-jack just an expansion of the original post. The lawyer crap defintely was, but it was entertaining none the less.:laugh3:
Thanks

[jeepdude10000]

In the posts people are mentioning APN headers for the XJ's. I have never heard of these before. I have looked into the Banks and Pacesetter ones. I have a 96 and have welded the header twice. I was going to buy the Banks one but by thime I have it shipped to the east coast of Canada it was going to cost me almost $700.

Rob

If u find a good one in Canada, let me know , i want to replace mine(no big hurry though, jepp runs great), Thnax

[falcon556]

8 Posts and that is one of them ? :sure:
I just took my Rig to the muffler shop and he said he can weld it with pretty good results , but of course no warranty, which was expected. I have to take it off because it is on the block side. It is a RE Stainless steel. The crack is about 2" long and very small. Almost heals itself when it is hot.
I really don't want to have to pull off all that crap for such a little crack unless I have to. So what is the best compound you guys who have had desent results with ? I would think cleaning and roughing up the surface is the key to good results. My crack is where one tube hooks onto the collection pipe at the weld. Very small.
Falcon this one isn't a hi-jack just an expansion of the original post. The lawyer crap defintely was, but it was entertaining none the less.:laugh3:
Thanks

Glad you had some fun :-)
I think that as manifolds go, the XJ must be one of the easiest to remove and reinstall. That IMHO makes taking a chance and having it welded instead of replaced, a resonable decision. Unless somebody knows for sure that they'l crack again all you have to loose is about $10 for the gasket and a few more for the heliarc.
BTW when you remove the intake, look at the valves. If you can see carbon deposits on them, you are not using a good gas with enough detergents. A bottle of injector cleaner may be a good idea.

[boise49ers]

Glad you had some fun :-)
I think that as manifolds go, the XJ must be one of the easiest to remove and reinstall. That IMHO makes taking a chance and having it welded instead of replaced, a resonable decision. Unless somebody knows for sure that they'l crack again all you have to loose is about $10 for the gasket and a few more for the heliarc.
BTW when you remove the intake, look at the valves. If you can see carbon deposits on them, you are not using a good gas with enough detergents. A bottle of injector cleaner may be a good idea.

I use Chevron. My motor only has 15 thousand miles on it too. The header was just replace when the motor was 3 years ago. Pisses me off ! Yeah I'll probably pull it after a club run we have next weekend. These guys at the muffler shop are really good too so I have confidence in them. If it cracks again it will probably be in a different spot. I should of bought a Banks when I got the new motor, but I was trying to keep costs down after approaching 3 grand on the motor swap.
Cya !