Welding a cracked exhaust manifold on a 99TJ?

[1TONTJ]

What's it made of? Can I weld it with my MIG? Or is it better done with a stick and some special rod?

Thanks,
Phil

[ol John Henry]

You CAN weld it, but I would BRAZE it:D


edit= Assuming its cast:rolleyes:

[1TONTJ]

Well I guess no DIY repair for me, I don't know anything about brazing...

Phil

[bigdude]

I say use JB Weld:D

[64Trvlr]

Originally posted by 1TONTJ
What's it made of? Can I weld it with my MIG? Or is it better done with a stick and some special rod?

Do not try to weld cast iron with your MIG it won't work. To get a good weld on cast iron you should V the crack with a grinder, pre heat the manifold with a torch, weld it with Nickle rod, peen the hell out of it with a ball been or chipping hammer, then cover it with sand so it can cool slowly and evenly. You might want to call around and ask the welding shops in your area for prices, and if they will even weld cast iron.
:cool:

[1TONTJ]

So the manifold on a 99 TJ is cast iron? I didn't know that.

Phil

[64Trvlr]

Originally posted by 1TONTJ
So the manifold on a 99 TJ is cast iron? I didn't know that.Phil

Me either, I made a bad assumption that since a post mentioned not being able to use a MIG that it was cast iron. Sorry for the bad info I passed along. Looks like I need to pull my head out. If it's stainless or steel tubing you should be able to MIG it with the right wire and gas.
:cool:

[Sundowner]

every manifold I've seen is tube steel, and the cracks usually happen becuase there's no flex point in the exhaust system. The weld repair will most likely fail again for the same reason. In (2000?) there was an "Accordian" revision to the manifold to prevent this. I'd look for a new manifold to swap in, or call Mike at Accurate performance, I think he sells refurbed manifolds for like $200

[1TONTJ]

So I could MIG it for now? (It's for my friends Jeep - and he has no money for a new 2000 manifold right now).

Be nice if it could hold for a season...

Phil

[Sundowner]

what's it cost to try?
nothing! :D
go fer it.

[CaptainFleXJ151]

It is steel tube header and not a cast manifold. It will fail again. Your best fix is an aftermarket header.

[Dust Puppy]

i feel your pain.... i keep busting my clifford header and i keep welding the piss out of it and it keeps cracking.. ok well by the time im done it will be all weld.

i dont think its worth welding to a stock manifold cause like the guys said its cast

[Turtleack]

Try taking it back to the dealer and talking turkey, it could be still under warranty as it is part of the air polution control system. The dealers have been known to replace the manifold with a new one for a nominal sum which doesn't even cover the labor for replacement, even beyond the warranty period or mileage limit. It is a known problem which it sounds like the factory corrected in 2000.

[1TONTJ]

Uh, no warantee I'm afraid. Don't think the dealer will warantee it in the 89 YJ it's in now ;)

Phil

[bigdude]

Uh, no warantee I'm afraid. Don't think the dealer will warantee it in the 89 YJ it's in now

What about yanking it and taking it in. Tell them you took the time to pull it just hoping that they would replace it due to the fact that they are prone to failure. My guess is they would help you out no problem. If you took the time to yank it and bring it in, and they already know it's a common problem, I think they would be pretty receptive to your inquiry.

[Oxjockey]

^ not a bad idea - considering all they have to do is hand you a new one, but then you'd have to prove it's from a vehicle with <80k miles and <8 yrs old.

[bigdude]

but then you'd have to prove it's from a vehicle with <80k miles and <8 yrs old.

I was kind of thinking that this is such a well documented and commonly occuring failure they would just replace it regardless of milage because it's obviously a design flaw from the factory.

[1TONTJ]

Just tried the dealer, and no-go on the warantee.

I will weld it with the MIG and we will see how long it lasts.

Phil

[Welby]

Weld it and use header wrap on it :D

[sfraser]

Originally posted by bigdude


I was kind of thinking that this is such a well documented and commonly occuring failure they would just replace it regardless of milage because it's obviously a design flaw from the factory.

The dealership told me it was $700 Canadian for a new one. I don't think they would just give them away.
Phil will just weld my manifold and we will see how it goes.
What's header wrap?

[Welby]

Originally posted by sfraser



What's header wrap?

http://store.summitracing.com/partdetail.asp?part=2359

[One Big Zuk]

I did one at my shop and had a guy tig weld it (don't have a tig) it has been over a year and not a problem. The guy said I could have miged it but he did it for 30 bucks.

[jeepxjga]

i had the same problem on my 92, i welded it, it cracked, welded it again, it cracked again so i said fawk it, spent 200 bucks and picked up a flexible one from napa, jeep really fawked everyone on this one, its a common problem :( stupid jeep engineers

[Sundowner]

stupid jeep engineers

:D

[emsoffroad]

Wasn't there a recall on the DC 4.0 manafolds? You need to find a dealer that wants to make money. My friend did this took his stuff in, the dealer made out a work order, for a fake car. Gave him the parts, and billed the mgf for the labor.

[Jeepinman]

Just MIG the focker......I did mine over three years ago and it's holding up fine.........Forget about paying for a new one. If you know how to weld, you should have no problem.

[Jeeper Tim]

This thread is really old - but I just welded one and was looking for input/bets on how long it will hold. I saw some pics somewhere of one welded like this so this is not my original idea. I cannot find those pics but found this thread while looking for them. Check these pics of my repair job - do you think it will hold? This is in a XJ my in-laws tow behind a motorhome. No off-road at all.

http://bigredheep.com/jeepernumerouno/images/content/Manifold%20Repair/DSCF0004.JPG

http://bigredheep.com/jeepernumerouno/images/content/Manifold%20Repair/DSCF0003.JPG

[jeepnmatt]

the 4.0L HO header (and the rest of the exhaust) is 400 series Stainless Steel.

they Mig weld just fine. i have welded a couple of them the exact same way that JeeperTim did and both have held up for years. i have also installed 5 Banks headers and know of 0 problems with them after about 3 years.

if it were me, i'd MIG it. Mild Steel mig wire should be fine, but i used SS wire both times.

[Sharp]

i have welded one up and it held up until the guy sold his XJ, after that i have no idea, but thats all he needed....

[JEEPRZ]

I welded mine the way jeeper tim did in 1998, still holding.

[Jeeper Tim]

I welded mine the way jeeper tim did in 1998, still holding.
If mine will hold that long I'll be a happy camper!:D

[MDDimmick]

I welded mine, it eventually recracked but lasted a while.

[billyji]

Just MIG the focker......I did mine over three years ago and it's holding up fine.........Forget about paying for a new one. If you know how to weld, you should have no problem.

Ditto !!!! Weld it

shoot I welded a friend of mines on the rig with a weld pac 100. I guess maybe that made it easier. my esab 300 gun would have been a tight fit....I think they all crack.
I personally bought a 97 tj engine with a Borla on it 3 years ago. I have had zero problems from it... for the price the other person paid I shouldnt though

Mike G -- Billyji

[Appalachian YJ]

Check out E bay auctions for an aftermarket manifold. There are a bunch of them for sale for less than $75.00. I started to order one, but bit the bullet and bought the Borla instead.

[geberhard]

Check out E bay auctions for an aftermarket manifold. There are a bunch of them for sale for less than $75.00. I started to order one, but bit the bullet and bought the Borla instead.


X2 you can buy one with the coil thingy on e-bay for about $50.

Gui

[CB87YJ]

my 4.0 is outta a 99XJ
bitch cracked about 6 weeks ago
i mig'd it 3 weeks ago with elcheapo harbor frt mig.

worked for me, and it was free and i didnt have to bust my nads with the bolts, just wiggled my hand and the gun in there and zapped it.

I'll re weld it for 10 minutes worth of free as many times as I have to.
I got other shiat i actually need to spend money on.

man-up, break out the mig, gitterdun,son

[geberhard]

No issue with welding it up, but the stock YJ and TJ (some XJ as well) manifolds sukc, so why keep doing it over and over again. There is a difference between gittersun and gitterdun it right. Whatever works, but I prefer to only have to do it once, and buying a new one for about $50-70 is not a bad deal, plus my time is worth something if it cracks again.. ;)

[muddawg95yj]

anybody got any experience with the ones on ebay? I think I have seen similar ones in 4wd hardware. Or, does anybody know what those coil things are and where to find them.... I could just cut and weld those on my stock one if it would make my welded cracks last longer.... I am a cheap bastard

[Chrisjeep7]

they work great, i have installed several and none of them have cracked. andif you order one from jeep they come with the coils. mine on my jeep is a factory replacement and it has the coils...no cracks for 10k

[sherminator]

I know that Thorley makes a header and I think you can usually pick them up for about $325 with gaskets. Might be the only reasonable option.