My little 2.5L sounds like it has a leak around the manifold area, and from what I've heard, they are prone to cracking. <img src="/forums/images/graemlins/zombie.gif" alt="" />
Has anyone here replaced a 2.5 exhaust manifold? Where should I get a new one? Any tips on this job would be appreciated.
Thanks,
Corona

don't worry about a replacement till you find the LEAK! Most likely it is a exhaust gasket.. Start the engine cold and FEEL with your hand for the leak. Do a good job of LOOKING for the leak. Don't go off half cocked!
If you must have one look on ebay for a used one.
Big JIm <img src="/forums/images/graemlins/pfft.gif" alt="" />

BJ,
I've tried to locate the leak by placing my hands around the area where it sounds like it is coming from, but I cant tell. It's not easy to reach, and stuff is hot. <img src="/forums/images/graemlins/scared.gif" alt="" /> You are right though, I should confirm what is actually leaking. It's bad when cold, and gets better as it heats up, but never completely goes away. My brother's YJ 4.0 sounds the same way, if not worse. <img src="/forums/images/graemlins/frown.gif" alt="" />
Should I try just removing/replacing the donut? Does it even have a donut?
How can I get a drawing of the parts? Is it available online? Am I asking too many questions? <img src="/forums/images/graemlins/drunk.gif" alt="" />

Wait till the morning and then put your hands on the manifold when it first starts. Yes it has a donut.
Big Jim <img src="/forums/images/graemlins/pfft.gif" alt="" />

I haven't heard of too many folks having a problem with the mainifold leaking with the 2.5, but thats not to say they have a common issue. The 4.0L for YJ's seem to go over time, and it is a somewhat obvious spot, where the front three and back three come together on a header. There is no way to repair it on the vehicle and taking it off and rewelding it can cause all sorts of mis-alighments and warping the mounting surface. I paid a shop to replace it on mine rather than dealing with sticky bolts/studs on the intake/exhaust. I'd go to a local muffler shop and get them to inspect it and give you a price for them to provide parts and do the work and see what they say. Then look for parts on-line at places like 4wd.com and others like them. Ebay does have a lot out there, but some prices for used stuff after delivery fees added in can be just as much as a new one.

I had a similiar issue.. I had to pull the head because the lug had broken off in the head and causing a leak.. You couldn't see or feel it but definately hear it.. Took to a local machine shop and they replaced the lug and also had it resurfaced while i had it off. After putting everything back together and replacing the exhaust manifold gasket.. It was like new

Thats 'zackly what I DON'T want to do, snap a stud off in the head. <img src="/forums/images/graemlins/barf.gif" alt="" /> I think I'll take it down to the local muffler shop and see what they think. I just hope their gentle with my baby ...<img src="/forums/images/graemlins/baby.gif" alt="" />
Thanks,
Corona

I didn't snap it off.. it had snapped off during a little mud run... <img src="/forums/images/graemlins/shiner.gif" alt="" />

Ouch <img src="/forums/images/graemlins/notooth.gif" alt="" /> <img src="/forums/images/graemlins/shiner.gif" alt="" /> <img src="/forums/images/graemlins/scared.gif" alt="" />