[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 [img]smile.gif[/img]

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. [img]graemlins/dunno.gif[/img]

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