Troublesome exhaust

[cc]

Any one help with some advice on exhaust leak. Close to manafold and looks like big job to repair or weld. Hoping to repair with mig otherwise big job removing a lot of engine parts to restore exhaust. Waiting for the money to stop spending on my Jeep - is this what is called a Jeep thing? Old 60 series, 398k and never spent a penny!!!!!!!!!!

Any advice/help would be appreciated.

[RogJK]

I had this recently - the TJ manifold is prone to cracking where pipes come together and is to do with heating up and cooling on short runs. Mine was just outside warrantee and only 48k. I asked around and ended up replacing it with aftermarket as repair was just not going to last and the system needed to be removed to be welded anyway, ie carb / intake stuff etc. Cost less than the $1100 plus labour for OE stuff and better system, I reacon at least 15kw more than before with freeflowed headers.

[Wooders]

I've also got a real bad exhaust leak....infact I think it's about to fall off...anyways I think I'm going to get a full Stainless Steel replacement from Suburban....Just gotto get around to organising it....

[big red beast]

if you guys are going to get new exhausts, i highly recommend HI-TECH MUFFLERS.
i dont care what ppl say, they know exhausts better than anyone is the business. - had a xr6 done there, only cat back, not even a high flow cat and they got 9kw out of it. that was recorded on ford's dyno with the car hooked up to they computers. just had a mate with a alfa GTV go in, did manifold back, as they already run a semi extractor system, high flow cat and this thing fly's. - thats only 2 of many cars that i know that have gone there and come out with big smiles.

i dont care if you can buy a bolt on from suburban, or theve done em before - and they know TJ's better than anyone, i assure you HI-TECH will produce a better exhaust for the money. - they do research into their systems before producing them. - anyways half the bolt on kits sold here in OZ are produced by them - they are under 4 company's or something i'm told and sell em all over Oz.

HI-TECH all the way - im saving up for one atm.

[Wooders]

BRB,
Whats' the likely damage of a full replacement setup??

[Steve]

I've heard Hi-Tech is pretty good. BUT I've also heard the headers they make for the TJ hang WAY too low for a serious offroader. You'd be likely to be running no exhaust after 5 minutes on a serious trail.

[Wooders]

Hmmm that's not good - can anyone advise just how much lower?
Although I'd think a 2" MML will help get it up higher....

[Steve]

Wooders,

From memory the cost was about $550 for the header only. Plus the same again in labour seeing how they have to remove the entire fuel injection system to put it on. There was someone on here or EJ at one point in time that had them. Can't remember. graemlins/dunno.gif

[oscar_the_grouch]

Steve n wooders i think gojeep has the hi tech headers on his xj graemlins/dunno.gif ...i think i saw his write up on his site

[merolius]

i have the same problem with my header cracked at the collection point , discovered when cat destroyed it self .tried fixing in car but made it worse . sounds like a truck now. so you have to remove efi grrr at that job .

[Kramer]

Yep, this is a common problem with the Stainless factory headers.

My 96 XJ was doing it when I bought it at 174k and I had it fixed at that time before paying the cash. You can't successfully repair this in the car, manifold off job for sure. You have to heat the manifold to a high temperature and keep it VERY hot whilst welding - bit of a specialist job. Take the manifold off and turn up at your local exhaust bloke at 5 pm one day with a nice bottle of Scotch smile.gif

The manifolds are not hard to take off, but you will need time. As in allow 3 hours to get them off (use a manual if it's your first time) and probably 2 hours to put it back together again (use a new gasket, they don't cost much). There is really nothing to the job - you just need a tool kit with various lengths of ratchet extentions to get to those manifold bolts. Have a go if you're confident. graemlins/dunno.gif

It will probably start cracking again right next to the weld in due course, but that's the problem with stainless. Extractors will affect insurance as well in most cases, so check with your insurance mob first...

"Gojeep" ditched his factory headers at 100k - read his writeup on his website it's called "Exhaust for Torque". He's very approachable but in Tassie at the moment touring for a couple more weeks.

Kramer

[Wooders]

Well after talking to HiTech I'm ruling them off my list.
They quoted me $2500 for the full system (inc headers) but that's only in mild steel...Stainless was another $200...$2700 is over double other quotes I got....

Just for reference: (First mild steel & second Stainless)
HiTech - $2500 & $2700 2¼" pipe. Wanted me to supply the gasket too.
Tuffy - $1600 & $1900 2¼" pipe. Custom built headers & tubing.
Midas - $1750 Mild only. Didn't think they was Stainless available graemlins/crazy.gif Didn't bother to ask about the tube size etc.
QuickFit - $1450 Mild only. 2¼" "sports" system.
Hornsby Mufflers - $850 mild only. 2½" But retains the stock cat....

hmmm decisions decisions tongue.gif

[ 08 January 2003, 03:09 PM: Message edited by: Wooders ]

[hoppy]

what happens if the cat is removed altogher
is it legal ?
any other parts need to be removed ?
performance worse or better
hoppy

[Kramer]

Removing the cat is not legal - EPA will send a pole up said arse if caught.

Use a hiflo cat. Minimum is a cat and one muffler. I ended up replacing the exhaust system with a 2 1/4 system, sports, hi flo everything. Initially I went without the resonator but ended up putting it in for drone reduction. $550 all up (not changing any pipework, that's just for the cat, muffler and resonator installed).

The car sounds great, and has heaps of go.

BTW the guy I went to is in Melbourne on Dandenong Road, near the Darling Road intersection in Carnegie, opposite Radio parts - drop in and see Domenic there if you're interested Melbourne boys.

Kramer

[ 08 January 2003, 05:02 PM: Message edited by: Kramer ]

[Rex]

I agree with Big Red Beast, HiTech know their exhausts. I called them to discuss what I needed, I'm adding a supercharger so want to do exhaust at the same time. They custom build the headers and muffler to give you what you want. Need the car for a week to get it just right. They did my wrx, best systems I've seen. Don't know about the height problem, will have to bring that up when I decide to do it.
Hugh G.

[Sureshot]

I was just going to get some mates in Bankstown to do the welding for me but by the sounds of it may be worth it just getting the full job done. From what I hear the cracks are going to keep coming back.

Maybe we could all get a good deal taking them all to the one place at the same time.....hmmm

[MR. 04 X IV]

I'm surprised that no-one has mentioned putting on a 4inch polished chrome muffler with a 6 inch tip, sticking out the back at some rediculous angle??? graemlins/headspin.gif
hehehehehe

[big red beast]

mate tuffy and midas are jokes, those guys do your standard everyday exhaust for sound not performance. if you are going to them, you might as well go cat back for $300 as the standard Tj has a high flow cat and a semi extractor system, so opening them up from cat back does make some difference. the reason you want an exhaust, i hope is for performance, expecailly if your going from the manifold, then i can only say hi-tech are the performance kings. no one else in the business goes and does research on the car to create the best performance possible.

you wouldn't be paying $1000 for nothing - if they were rip off mechants they wouldn't be packed everyday of the week - mate they have a anme to uphold, especially to sell at the price they do - this isn't done by being the same as everyone else but by being better.

i have personally been 3 times to get exhausts done, for either my/brothers cars and mates and 2 out of the 3 times have seen race cars up on the hoist, not to many local guys do race spec exhausts on a regular occasion.

try CARLINE MUFFLERS they are also pretty good and are said to be cheaper than high-tech.

if you want an everyday exhaust, then go to Australia's Best - they are decent and cheap - better than tuffy and midas (midas is fucken shocking!!!) these are noise exhausts not performance.

can i ask a questions, whats making you go for 2 1/4 not 2 1/2, is that what was recommended to you? or do you just want that? who recommeneded it?

[Wooders]

BRB,
Thanks for the feedback.
To be honest I've done bugger all to the exhaust of ANY rig I've owned - so I'm FAR from knowledgable.
As for the 2½" v's 2¼" all but Hornsby RECOMMENDED 2¼"....

[big red beast]

seriously try CARLINE they are also meant to be very good from what i am told and as mentioned are said to be cheaper than hi-tech.

2 1/4inch, tahts weird as i have been recommended everything from 2 1/2 to 3 inch and inbetween.
actually it does make sense as you are openming up from the manifold whese as i was only considering cat back.

[AussieCJ7]

Originally posted by Kramer:
Removing the cat is not legal - EPA will send a pole up said arse if caught.

Kramer<font size="2" face="Verdana, Helvetica, sans-serif">I have one of the very few factory made unleaded vehicals that does not have to run a cat by law graemlins/madfinger.gif graemlins/avid.gif

1983 CJ7 was pre unleaded in Australia but the US had already switched over I think there is only about 12 months overlap where this is a leagal combo