Topic: Fixing exhaust leak

[neale_rs]

The rearmost stud is broken on my 2.5 4cyl (95 YJ) and it has an exhaust leak.  It was this way when I bought it so I have no idea how long it has gone like this.  Yesterday I took it to a mechanic and he said that he could just remove the manifolds and broken stud and put in a new gasket but that there is only a 50% chance it will seal properly.  He said the sure fix is to mill the exhaust manifold and mating surface on the head, stating that the exhaust leak could have erroded the mating surfaces.

Does this sound reasonable?

Also, would the intake manifold also have to be milled to keep it at the same thickness?  I worry about this because some of the fasterners are used to hold both manifolds in place.

Thanks

[Mozman68]

just curious...how much is he asking to do that??

[oldjeep]

Depends on how much of the gasket got burned up.  When I got mine one of the studs was missing, didn't notice until a few weeks ago when I started it up.  Replaced the stud and cranked down the washer/nut - exhaust leak all fixed.   Milling it seems extreme, if it's pitted I'd try some of that permatex repair goo. It worked for me the last time I had a pitted header that wouldn't seal.

http://www.permatex.com/products/automotive/specialized_maintenance_repair/exhaust_system_maintenance_repair/Permatex_Hi-Temp_Metal_Repair_Compound.htm

[neale_rs]

Mozman, 
He is asking $100 for the smaller job and $200 for the big job.

oldjeep,
Thanks for the input.  Milling does seem extreme to me.  I may tell him to do the smaller job and see how it goes.

[jcsanders79]

Look into getting a header instead of the manifold, pacesetters are inexpesive and are not to hard to install, $160 for a YJ @ tellico4x4.com then $0 for labor DIY

[oldjeep]

You can buy brand new exhaust manifolds on ebay for $40 any day of the week too.
http://cgi.ebay.com/ebaymotors/91-02-JEEP-CHEROKEE-WRANGLER-2-5L-EXHAUST-MANIFOLD-2-5_W0QQitemZ160093426673QQcmdZViewItem?hash=item160093426673

[Jeffy]

If done properly, replacing the stud and gasket will fix the problem.

[lanulos89]

like jeffy said, i originally bought the jeep bolt broken, took it apart drilled the old stud out, put it tpgether with stock manifold.  worked fine, then upgraded to header, and well it still worked fine so yea you dont to mill just do it correctly.

[SKI BOY]

If you don't know and trust the mechanic, you may be paying $200 for him to replace a $5-10 gasket! The manifold & head would have to be severely pitted for a new gasket & bolt not to seal the leak. If the mechanic is honest he would tell you that once he has it off. Let the buyer beware!! 

[neale_rs]

Thanks for your advice.  I'll talk with him again and see what he is willing to do.  Maybe he was just giving me the worst case scenario.  I have never taken a vehicle to him before but he is highly recommended by the local jeepers.