Manifold to cross pipe donut

TLT1964

TJ Enthusiast
Original poster
Joined
Jul 15, 2021
Messages
276
Location
Ohio
I'm putting new exhaust on and the old donut between the manifold and the old pipe is pretty well seated. Should I knock it off before using the new donut?
 
Are you sure there is a donut there? I was thinking most I have worked on were the bell style that didn't use a gasket
 
The kit came with a gasket curved on one side and flat in the other. There is a silver gasket on the manifold now where the old pipe came off, but it's squished to the shape of the old bell.

IMG_20230908_123230712.jpg


IMG_20230908_123242064.webp


IMG_20230908_123251394.webp
 
My 97 had a lead donut in it that was stuck in the manifold so the new one was a no brainier. But that thing added nearly an hour to the install! I had everything pretty well buttoned up, including new motor mounts and when I tried to bolt the two back together the donut created a gap to where the bolts weren't quite long enough to get the nut to bite. I needed about 4 extra arms!

I managed to use a floor jack to help lift the cross pipe up a bit and eventually managed to get the nuts to grab enough. I was sore and sweaty from that one! I probably could have gone to the hardware store and just bought longer bolts in the time it took to get it attached 😑
 
I'm gonna see if the old one will come off before I try the new one. Still waiting for FedEx to deliver the cross pipe, Rockauto sent the kit in three separate deliveries, all on different days 🤔
 
I wondered about this when replacing the downpipe on my 97 2.5. My notes are here, and they include some findings about the 4.0.
 
I'm gonna see if the old one will come off before I try the new one. Still waiting for FedEx to deliver the cross pipe, Rockauto sent the kit in three separate deliveries, all on different days 🤔

Yeah, Rock Auto has many different warehouses, and you have to check to see where your parts are shipping from. There is a separate shipping charge for each different warehouse. I try to choose the parts that ship from the same warehouse to get lower shipping charges and have them in the same delivery.
 
I wondered about this when replacing the downpipe on my 97 2.5. My notes are here, and they include some findings about the 4.0.

Great notes and advice. I'll try the seal once the pipe comes, FedEx never delivered it even though tracking says it was out for delivery 😡
 
Well, to my surprise the FedEx guy came right before 7pm. He wasn't having a good day, didn't ask what happened.

Will get it all buttoned up tomorrow. Haven't driven the TJ for over a week, having withdrawals 😞
 
  • Like
Reactions: bbaldwin237
My 97 4.0 has that seal.

Just made a new stainless downpipe and installed a new cat today. Wasn't happy with front driveshaft clearance, wanted a flex pipe and a v band in front of the skid plate. Welds are terrible but I'm wrapping it in exhaust wrap as soon as my O2 bungs get here next week.

IMG20230908170602.webp


IMG20230908163326.webp


IMG20230908093900.webp


-Mac