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

[97 TJ - I dont wave]

Well the up side is I can swap out a header, start to finish, in an hour.
I think if this next one cracks I will ask for my money back (good luck) and try the Doug Thorley Tri-Y design.
I am still on a mission to sell the 5.7 hemi idea to the wife... I will get there.....some day.............

[Jeffy]

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

The problem is they do not do long term testing and the I4 and I6 vibrates a lot.  The 2.5L more so.  Most companies don't do long term testing which is why many of them are breaking.  Even the stock manifold aren't impervious to cracking in similar locations.

[FourbangerYJ]

My Jeep was one of 3 that Banks used to R&D the 2.5 header. It was down there for a couple of weeks. I don't think they took the stock manifold off.  It took me over a year to recieve my free header. I left it in the box for over a year, I took it out only to take PICS to sell.
I had bad luck with headers in the past so I didn't want to mess around with them again. 

[dwtaylorpdx]

My Doug Thorley was put on almost 7 years ago,
Its never had a issue.

I've had to replace the rest of the exhaust system on my jeep
probably every 2 years since 1994, usually because
some part broke, mufflers, cats, hangers. I ran a
Inovate Diagnostic system on it for a couple days,
the fuel "curve" is way lean just off idle. I went through
3 stock manifolds before the Tr-Y went on. I've learned not
to run it low on fuel either, it can run super lean in a turn from
about 1/4 tank and down.

I still break off the rear manifold stud about once a year.

Its a Jeep thing 

Dave

[Jeffy]

My Doug Thorley was put on almost 7 years ago,
Its never had a issue.

I've had to replace the rest of the exhaust system on my jeep
probably every 2 years since 1994, usually because
some part broke, mufflers, cats, hangers. I ran a
Inovate Diagnostic system on it for a couple days,
the fuel "curve" is way lean just off idle. I went through
3 stock manifolds before the Tr-Y went on. I've learned not
to run it low on fuel either, it can run super lean in a turn from
about 1/4 tank and down.

I still break off the rear manifold stud about once a year.

Its a Jeep thing 

Dave

Too bad Doug Thorley's Jeep headers are out of production.

[dwtaylorpdx]

Ya, They went bankrupt at one point and are now owned by someone else I heard.

Didn't know they discontinued the header for the jeep though.

Maybe a stream of emails from the group would bring them back?

Dave

[Jeffy]

Ya, They went bankrupt at one point and are now owned by someone else I heard.

Didn't know they discontinued the header for the jeep though.

Maybe a stream of emails from the group would bring them back?

Dave

I doubt that will help.  Too few and on a discontinued engine.  I'm like Scott and sticking with the stock manifold.  I should replace the downpipe to route it around the oil pan instead of over it though.

[TN00TJ]

Dadgum, Guys.

I'm just getting ready to reassemble my motor with the Banks header (already paid for and lying on the floor by the TV here in my office) and now I'm getting REAL nervous.

Is this a widespread malady with Banks 4-popper Jeep header?

[97 TJ - I dont wave]

Do worry about putting the banks on your new motor. The header has a lifetime warranty and after 2 years you will be able to swap headers in your sleep.
......The Glass Is Half Full.....

[dwtaylorpdx]

I doubt that will help.  Too few and on a discontinued engine.  I'm like Scott and sticking with the stock manifold.  I should replace the downpipe to route it around the oil pan instead of over it though.

Problem for me is that the Thorley so far is one of the best performance mods I have,
Switching from the stock to it was night and day on power and mileage, literally gave
me a gear back on a hill on my commute. Mainly in the torque department...
Besides, after buying 3 of the stock manifolds in 2 years....
If I had it to do over again I would season the manifold
thoroughly before installing.
( Heat the manifold up to 600+ and keep it there for a while then let it cool down slowly over several hours... )

My current pipe runs under the tranny just behind the bell-housing. I did see
one that ran down and around the front of the oil pan though. Which if there
was room to fit the cat up there would be sweet , should put less heat into the floor of the jeep.

I've been practicing, I'm going to build another header based on the
thorley design but with some changes

Dave

[97 TJ - I dont wave]

Don't worry about putting the banks on your new motor. The header has a lifetime warranty and after 2 years you will be able to swap headers in your sleep.
......The Glass Is Half Full.....

[97 TJ - I dont wave]

Here comes # 6 boys, cracked again. It cracked right at the 6 month time frame. I have been driving it with a leak for the last month. I will take it off this next coming weekend (hopefully) and send it in for another. Appears to have cracked in the same spot the first FIVE did. I'll take pics next weekend.
I need to speed up my Hemi project so I don't have to fight this thing anymore. You would think the engineers at Banks would figure it out...
Aren't lifetime warranties great.
 

[cz777]

here is my .02 cents breaking exhaust manifolds yes you have heat and cooling also vibrations AND flexing OH hell of a mix of things  at work here ! i use never seize on all bolts and flanges next exhaust spring washers from ford's 300 when i can -- the best way is to read the hows and whats  on fasteners and washers ,springs also read about torque pattern and specs --if you figure ''8' tighten the bolts on your exhaust manfold and break the torque specs into 3 steps and wait 20 mins with each step. so steel or cast iron will seat evenly for a better seal -ok 15 fps wait 20 mins again 15 fps next 30 fps etc  i know this is a pain but it works i learned this one from working on  MB's  for years  still do! yes i drive a jeep !

[97 TJ - I dont wave]

Been down that road too.
From injector swaps to power chips to everything else you can throw at it. Bottom line is I could have had a Hemi at this point.
Will not make the same mistake twice. With the combination of upgrades I have there is no way around this issue other than reprogramming the computer at this point. I am done.
I will string the 4 banger along till the Hemi is in. I may crack 2 more headers before then though... See my Hemi thread.
Working on piecing a Hemi swap now.

[Jeffy]

You running poly engine mounts by any chance?