Topic: 2.5 liter exhaust manifold - banks - Cracked again!

[jfrabat]

I would go back to the flex pipe idea as I've heard of that being the solution to prevent the 4.0l header from cracking.  For $40 it can't hurt to try.  I guess try to install it on the downpipe before the cat? - probly have to cut out part of the downpipe and then strap on the flex pipe.   Anybody install one before and what location did you use?  Also what is the diameter of the downpipe?

http://store.summitracing.com/egnsearch.asp?N=700+4294923429+4294820497+115+4294814707

When I re-did my exhaust last week, I installed a flex pipe before the cat to avoid any possible issues with cracking...  I wanted to place it in the downpipe itself, but because of the O2 sensor, I could not.  So far, I am happy with it.

[cwildmann]

what size flex pipe did you end up using?  Have a link to the specific one you used?

[jfrabat]

what size flex pipe did you end up using?  Have a link to the specific one you used?

No, I dont have the part number; I bought it at a local mufler shop (stainless steel, same diameter as the downpipe - 2.5 inches IIRC)

[97 TJ - I dont wave]

Alright, the latest... I did not get the new header yet due to messing with a few more things first. I replaced the upstream and down stream sensors, and I am running oem plugs (tried them all, oem is the best) rotor andf cap are new. I ordered (from five 0) new injectors that are 22 pounds (like stock) but have 4 holes for better atomization. My harness also plugs right into them. They are the Ford blue (I'll get part # out later when I receive them -purchased today shipping today) I'll put in the new injectors, then replace the header with yet another Banks and hope for the best.

Having a flex tube is not the issue because you can clearly see the heat stress near the collector. The thermostat is not the issue because I had the problem before I even did that.

Once I have the new header on I will update again... This is getting expensive..
I will win this war.... Then when I figure it out, I'll trash the 4 banger for a 5.7 Hemi... I am on a quest!!! If I have to take a 2nd and 3rd out on this house I will figure it out.....
Thank you for all your input above, they are all valid points.
 

[97 TJ - I dont wave]

Also... I have never had any heating problems, I just put the flow cooler pump in "because" and the 180 thermastat due to the stage 2 Jet chip. I had the cracking problem before any of these mods...
By the way, the stage 2 jet chip gave me at least 3/4 of one horse power, great buy!  Save your money and buy a microbrew and case of Arturo Fuente Cigars instead, your money will be better spent.

[97 TJ - I dont wave]

Alright, injectors came in today. They are the dark orange Ford racing injectors # 0 280 156 013.
I will swap the injectors and header in the next few weeks...
 

[jfrabat]

I would go back to the flex pipe idea as I've heard of that being the solution to prevent the 4.0l header from cracking.  For $40 it can't hurt to try.  I guess try to install it on the downpipe before the cat? - probly have to cut out part of the downpipe and then strap on the flex pipe.   Anybody install one before and what location did you use?  Also what is the diameter of the downpipe?

http://store.summitracing.com/egnsearch.asp?N=700+4294923429+4294820497+115+4294814707

I have a flex pipe before the cat, and no problems with cracked headers...

[tony_dt]

Silly question. Anyone check or replace their cat? I had cracked exhaust manifold then I put a rebuilt motor in my Jeep with a Banks Header. It seemed about the same power as the motor before I changed it but not as powerful as when the jeep was newer. I had an issue with the Banks header mating to the stock exhaust (pre cat). I had a muffler guy change the flange on the stoc (pre cat) pipe. I was going to have him put flex in but he said it didn't need it. I also changed the cat to an aftermarket one and wham bam thank you ma'am, more power than I have ever experienced with my jeep before. It is not sports car but it gets up and goes now. Aside from a little overbore, Airraid intake and banks exhaust all else is stock. Anyhoo, I hate cats and I have had bad luck with them. Best investment I have made yet was replacing it.

[jfrabat]

Silly question. Anyone check or replace their cat? I had cracked exhaust manifold then I put a rebuilt motor in my Jeep with a Banks Header. It seemed about the same power as the motor before I changed it but not as powerful as when the jeep was newer. I had an issue with the Banks header mating to the stock exhaust (pre cat). I had a muffler guy change the flange on the stoc (pre cat) pipe. I was going to have him put flex in but he said it didn't need it. I also changed the cat to an aftermarket one and wham bam thank you ma'am, more power than I have ever experienced with my jeep before. It is not sports car but it gets up and goes now. Aside from a little overbore, Airraid intake and banks exhaust all else is stock. Anyhoo, I hate cats and I have had bad luck with them. Best investment I have made yet was replacing it.

I replaced mine because it was blown out (you could literally see through it!), but no difference in perofmance when I installed the high flow one (except now the exhaust is a bit cleaner)

[97 TJ - I dont wave]

BOSCH/Ford Racing (0280156013) injectors are installed. Runs alot smoother but I do not notice any horse power gain.
4th or is it 5th Gale Banks header is now in, thank god for the lifetime warranty. The one I sent back has the cracks in the exact same spots as the other Banks headers.  Hopefully the injectors will atomize better and let the exhaust run cooler. If not I will be swapping another Banks header in 6 months. I did put in a new magna flow cat about 2 years ago. I am trying to download some pics but I am having a hard time.

[97 TJ - I dont wave]

Also, I replaced the upstream and down stream oxygen sensors.... Just a shot in the dark.

[97 TJ - I dont wave]

Here's one spot the Banks headers have cracked each time. Notice the color change at the collector versus the down tubes. This is due to the exhaust heat...

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[97 TJ - I dont wave]

Here is the money pit.

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[97 TJ - I dont wave]

The new vs old, with old being 6 to 8 months.

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[sharpxmen]

Here's one spot the Banks headers have cracked each time. Notice the color change at the collector versus the down tubes. This is due to the exhaust heat...

that is obviusly a design flaw - they should've figure it out by now and change it, can't believe they keep selling it that way. Thumbs down for Banks on that one