2004 TJ Rubicon - Cracked Exhaust Manifold

[Rubicon]

Just found out that, surprise, surprise, the exhaust manifold on my 2004 TJ with about 95,000 miles has several hairline crackes - not bad enough to need "immediate" replacement, but will be done in the next month or so.

I'm about 99% sure I'm going to replace with the Banks Torque Tubes Headers. Wondering how others have fared with the Banks Headers. I've read quite a bit on-line, but seems most information is coming from "industry" sources....

I am also wondering if anyone has had them "ceramic coated" to hopefully help keep the heat down. I know Banks will void the warranty if using a "wrap" product, which my dad has used in years past on his Series Land Rover (with mixed results). I'm looking to make sure the heat under the hood stays somewhat reasonable (at least cool enough that plastic parts under there don't start melting down).

 

[jeep-N-montero]

I know 3 guys running the Banks header and they are happy, not sure if they had it ceramic coated or not though. Why do you have it listed as a mod if it isn't even on the Jeep yet? And the I6 has a header, not plural headers as a v8 would have.

 

[JeeprJack]

the 2002-2006 TJ and LJ came with a 2 piece manifold on the straight 6 engine. The back manifold in notorious for cracking.

 

[jeep-N-montero]

the 2002-2006 TJ and LJ came with a 2 piece manifold on the straight 6 engine. The back manifold in notorious for cracking.

All of the I6 exhaust manifolds are known to crack easily. 6 years ago I had a stock manifold welded up and gusseted and it is still going strong.

 

[Rubicon]

The rear manifold is the one that cracked for me.... Also, to Black ZJ, I went ahead and updated my "signature" to say (coming soon) on the header/manifold

 

[bob91yj]

I know 3 guys running the Banks header and they are happy, not sure if they had it ceramic coated or not though. Why do you have it listed as a mod if it isn't even on the Jeep yet? And the I6 has a header, not plural headers as a v8 would have.

Whew, glad to see the signature police are on duty!:Wow1:

 

[Jim K in PA]

Was this with the cast iron manifold? I know some TJs had the tubular steel manifold. My '05 LJ has the cast iron manifold. Have not detected any leaks, but have not looked for any cracks either. Where is yours cracked? Any pictures?

 

[Rubicon]

My understanding is that it is cast iron. No picutres yet. The shop said that there are "several hairline cracks" near where the flange mates with the Cat. I haven't had a chance to crawl under there with a camera. If I get a chance today or tomorrow I will post pictures.

 

[Jim K in PA]

Gotcha - thanks. I will take a peek at mine and see if i have any. I have about 115k miles on my '05 LJ Rubicon.

 

[Rubicon]

All Fixed Now!

Wanted to update everyone that I finally had the Banks Header/Manifold installed. I purchased directly from Banks Engineering & then sent it away to Jet Hot Coatings in Arizona to have it "Jet Coated".

I am tracking my mileage to see if there are any improvements. By replacing the exhaust manifold and the gasket, the very annoying whistle has also been resolved!

My original manifolds were both cracked - one with a hair-line crack about 1/4 of the way around (on the front), and with a crack wide enough to slip a credit card into, running about 7/8th of the way around....

 

[Hill Bill E.]

Wanted to update everyone that I finally had the Banks Header/Manifold installed. ...

I hate to say it....but you need to update your sig ,ine again to reflect the installation....:elkgrin:


:coffeedrink:

 

[K2ZJ]

I hate to say it....but you need to update your sig ,ine again to reflect the installation....:elkgrin:


:coffeedrink:

HAHAHAA! I was thinking the same thing!

 

[x32792]

Banks Header on TJ = Improved milage? Don't toy with us....Post some numbers....Please.

 

[Rubicon]

Alright, alright, my signature has been updated! Sorry for pushing buttons & tweaking pet-peaves!

With respect to mileage, I've only been through about 1 1/2 tanks, so I don't have enough data yet to reach conclusions.... but that being said, I did run about 100 miles on the highway (up and down hills - from Tustin to Pasadena area via the 57 Freeway for those who are around So Cal), and got about 17.5 mpg. On previous trips, I've averaged about 15.5 (before install of the Header and Monster Exhaust). I will provide updates as to mileage changes as time goes by. I'm kinda anal about tracking my mileage - I've recorded every tank of gas I've put in her & the milage at each stop....

 

[Rubicon]

To Bill... Should I have updated my Signature Line, or my "sig ,ine"? But honestly, I have no idea what a "sig ,ine" is.....:wings: