How To Replace Manifold Gasket & Fix Broken Bolt || Jeep Sputtering E04

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Exhaust Manifold Bolt Broke

Replace our exhaust manifold gasket and repair a bolt that is broke. Have broken plenty of bolts in the past, not a fun job to do. If we left this we would end up with a burnt valve in the head, that is a job we really don’t want to do.

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Removing the Intake and Exhaust Manifold on a Jeep Wrangler YJ - Chris Does What TN

Tools and parts:

First, we have to take the Intake and Exhaust Manifold Off or Jeep Wrangler

Taking off the intake and exhaust manifold is not too hard, but just to get to it there are a bunch of vacuum hoses and wires. Then once done with all that, the power steering pump and the mount has to be removed. Removing the Jeep’s power steering pump and the bracket is pretty easy, it’s putting it back that will try your patients.  Now that we have a clear path, we can remove the intake, followed by the exhaust manifold.

  • 01:57 Over of what we are going to do to Replace the Exhaust Manifold Gasket and Tap the Broke Bolt
    Go over of what we are going to do to - Chris Does What
  • 02:04 Remove the Air Box on a Jeep Wrangler YJ
    Remove the Air Box on a Jeep Wrangler YJ - Chris Does What
  • 03:09 Remove the Power Steering Pump on a Jeep Wrangler YJ
    Remove the Power Steering Pump on a Jeep Wrangler YJ - Chris Does What
  • 05:09 Removing the Vacuum Hoses, Wires, and Injector Plugs On A Jeep Wrangler YJ
    Removing the Vacuum Hoses, Wires, and Injector Plugs On A Jeep Wrangler YJ - Chris Does What
  • 09:50 Removing the Intake and Exhaust Manifold on a Jeep Wrangler YJ
    Removing the Intake and Exhaust Manifold on a Jeep Wrangler YJ - Chris Does What

Broken Exhaust Manifold Bolt or Stud on our Jeep Wrangler

As we said, this is not our first broken bolt, probably won’t be our last, always a pain to fix when it happens. There is plenty of places you can source your tap set for your newly discovered misfortune, if you click here to get your tap set, it helps us out. 

Now let’s get this taped, most of the time we go from a smaller to bigger bit, depending on how big the tap is. Once we have drilled with the correct size bit we can start tapping our new hole. As we thread the newly drilled hole, we are very liberal with lube. We will turn the tap around 2 full turns, then bak it out and spray lube. Once we hole is threaded, with then run our bolt all the way down making sure we have good threads.

  • 12:10 Drilling And Tapping the Exhaust Manifold Bolt on our Jeep
    Drilling And Tapping the Exhaust Manifold Bolt on our Jeep - Chris Does What

Putting the Exhaust and Intake Manifold Gasket for our Jeep Wrangler

Nothing like having an exhaust leak. Not only do exhaust leaks sound bad, but they can also damage your car’s head. When we took our exhaust manifold off our Jeep Wrangler it didn’t have a gasket, either meaning that we are the first to do this, or the previous owner forgot to add it. The only time you don’t have to use a gasket is if you have two exact surfaces coming to gather, but in the video, you can see this is clearly not the case.

  • 14:43 Installing an Intake Exhaust Gasket on a Jeep YJ
    Installing an Intake Exhaust Gasket on a Jeep YJ - Chris Does What
  • 18:05 Getting the engine wiring in the right spot for our Jeep
    Getting the engine wiring in the right spot for our Jeep - Chris Does What
  • 25:24 Install Power Steering Pump and Belt on Jeep Wrangler YJ
    Install Power Steering Pump and Belt on Jeep Wrangler YJ - Chris Does What

Takeaways for Bolt Tap and Manifold Gasket Install

While we have installed many gaskets, getting to them has their specific challenges. The hardest part of this job was taping the bolt and the install of the power steering, but the overall job is fairly easy and can be done with limited tools. 

  • 32:39 Wrapping Up the Jeep Exhaust Manifold Repairs
    Wrapping Up the Jeep Exhaust Manifold Repairs - Chris Does What

Tools and parts:

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