Manifold/header/muffler/tail Pipe problems of the 1997 Jeep Wrangler - part 1

I am in the process of replacing the exhaust manifold on my 1997 Jeep Wrangler for the second time. The first one failed at approx 55k miles (out of warranty) and Chrysler Jeep customer service denied existence of a problem with the exhaust system, in spite of numerous reports of manifold failure on many internet automotive sites. The replacement part was supposedly redesigned to prevent recurrence of the problem, but it has now failed (mileage is now 110k, so these are 55k parts!) and must also be replaced. The mechanic stated that the replacement parts just crack in a "new spot". Chrysler Jeep has been totally unresponsive to what is obviously an engineering flaw in their product, and sticking their customers with the bill and any resulting safety issues! not a great way to build your customer base!.

Consumer noticede a loud noise while driving and exhaust fumes coming into the vehicle. Consumer took vehicle to dealer for inspection. Dealer informed consumer that vehicle had multiple cracks on the exhaust manifold, and it was not covered under a recall.

I have a 97 Jeep Wrangler. I have a problem everytime I start my Jeep after it sits for 20 min. It sounds like it wants to shut down and after pressing the gas to the floor it finally kicks in and takes off. I lose power alot and it backfires . I have had the exhaust manifold /catalytic converter replaced and a broken stud in the exhaust manifold to head assembly. This has been going on for 3 years and I have taken it to several differnt Jeep service department. All the service departments can tell me is that they can't find the problem but they always seem to find something else for me to pay for . I'm still having this problem and now it's getting worse . What can I do? please help.

There was an exhaust smell entering the compartment of the vehicle and there was a loud noise coming from the engine compartment. The owner took the vehicle to a dealership and they indicated that there was a crack in the manifold. The manufacturer was contacted but state that there was nothing they could do because the vehicle was out of warranty. The consumer believes this component should be recalled.

1997 Jeep Wrangler sport 4. 0 liter exhaust manifold crack noted at approximately 60,000 miles. Mechanic stated it appeared to be welded, no one had previously welded exhaust manifold. My understanding is that the exhaust manifold in this year tends to crack. Is there a recall by the Jeep dealership? if so, I have not been notified. Also the throttle control sensor as well as O2 sensor effected at this time. Vehicle now has 81,000 miles runs poorly has visual crack at the exhaust manifold in two different areas. The only recall I have read about is the air bag but I have never received a notice from Jeep eagle or the Chrysler company. Can you help me? who do I contact, and if the exhaust manifold is commonly known to crack - without cause why wasn't I or possibly others notified? who can I contact? the exhaust manifold according to others is more prominent than the air bag recall.

Exhaust manifold cracked in three places. Strong fumes entering vehicle, could cause driver to pass out behind the wheel. Lots of complaints about this same defect on your website.

My 1997 Jeep Wrangler sport that has 52000 miles on it developed cracks and breaks in the exhaust manifold. With these cracks and breaks excessive amounts of exhaust fumes leak into the car. After doing some research on the internet this problem apparently is very common. There are many pictures of the exact cracks and breaks on the exhaust manifold from many diff people. It was suggested in one forum that Jeep fixed this issue in the 2000 model Jeep.

I bought my 1997 Jeep Wrangler in June, 2002 from a used car dealer in baltimore, MD with an as-is warranty and was told the vehicle had passed inspection and was in good condition. It had 64,000 miles on it and appeared to be good. Since then I have had nothing but problems with this Jeep. First the wiring harness, then the transmission, now a diagnosis to replace the intake and exhaust manifold, replaced fuel pump and has a faulty fuel gauge, and possibly the stabilizer bar or steering components. This Jeep is costing me more in repairs than the actual value of it. I fear that it is unsafe and that I m facing more expenses if I keep it, but I am still making payments on it. Do I have any recourse as far as lemon law protection, recalls, help!!! I don't know what to do with it.

Engine manifold has gone out twice while consumer has been driving. Contacted dealer, and dealer replaced the part, but the problem still occurring.

Engine exhaust manifold cracked just before where weld is located crack is over half the diametar of the pipe after reading over 30 complaints on the same or simular problem I can not understand why there is not a call back on this problem there is no dought that it can cause if not found in time a sever harm to the vehicle and possibley to all in the vehicle.

Cracked exhaust manifold on 97 to 2000 Jeep tj Wranglers. Missing exhaust "according" missing resulting in cracked manifold. Resulting in car failing us epa smog guidelines. In search of tj owners showed many owners having this problem.

Manifold cracked in two places! I have never even taken it 4-wheeling.

Engine was very loud, so I took the vehicle to the dealer who said it was a cracked exhaust manifold. I asked if this is a problem with the wranger and was told that they were not aware of any recalls. Contacted a few Jeep clubs via the internet and found out that the cracking of exhaust manifolds on Wranglers is very common, to the point that you're lucky if your's doesn't crack, and that the manifold has since been redesigned. I contacted the crysler customer service center on the internet to find out if there was a problem and if in fact the manifold was redesigned as I wanted to make sure that I wasn't just installing another defective exhaust manifold. There are aftermarket exhaust manifolds that carry an unlimited warranty and are in fact less expensive, unfortunately there is a heavy demand for them with a long wait. Chrysler customer service would not provide me with any information, just boiler plate responses thanking me for contacting them. I ordered a new replacement exhaust manifold from the dealer, and when I went to pick it up, both the service and parts managers indicated that they new of no problems with the Wrangler exhaust manifold cracking. When I asked if the manifold was redesigned, they indicated that they did not know. When I got home and opened the box containing the replacement manifold, it is obvious that the manifold was indeed redesigned! they added bellows thermal expansion joints in the first and sixth exhaust pipes. Apparently the length of the manifold coupled with thermal expansion, just rips apart the manifold. While I did not have a fire in my engine compartment, as some have had, the underside of the intake manifold was black from the leaking exhaust, and was indeed evident in the car when driving. Repeated contacts to the internet Chrysler customer service ended with them cutting off communication. I have digital pictures of the old and the redesigned manfold. I am very disapointed in how Chrysler has handled this issue.

Exhaust manifold has cracked twice in 20,000 miles. The dealership admits a problem, Chrysler customer service does not. I found a boatload of complaints on the internet about the same "Jeep" problem but no one will address the issue.

A pipe that comes from engine manifold has cracked. When driving it makes a loud noise. Please provide more information.

Exhaust manifold cracked 6/21/01, local Jeep dealer had no recall, not under warranty. I was in the process of finding a better aftermarket replacement manifold when on 7/19/01,while stopped w/ engine running, the plastic hydraulic line for the clutch melted from the excessive heat, and caught on fire.

The exhaust manifold cracked nad with end a week was broken in several places. I contact Jeep and several dealers ablout the problem. All said that this has not been a common problem and havent even heard of this happening. After looking the problem up on the internet I found well over 300 documented cases. Jeep strait out lied about the problem and has refused to help resolve it.

Exhaust manifold has developed a crack which allows exhaust fumes to escape into passenger compartment. Vehicle doe not meet emissions test requirements.

Crack in exhaust manifold @ pipe union allows exhaust fumes to enter vehicle. Also, power steering fluid leekage from steering gear box requires complete steering gearbox replacement @ cost of $1350 on car w/ 49,000 miles.

The exhaust manifold cracked and broke off.

Weld on exhaust manifold failed due to normal heating and cooling.

Exhaust manifold cracked about 2 inch which may cause manifold to drop while driving. This could result in a loss of vehicle control. Please provide further information.

Same as everyone else. . . . Cracked exhaust manifold on 4. 0 l 6 cyl. Jeep has redesigned part. I formerly worked with a 4x4 repair shop, and almost everyone that came in with a 1997-2000 (or so) Jeep had same cracks. Leading 4x4 magazines state "it's not if it cracks, it's when". Given this many complaints, Jeep should be paying to fix their flaw, not consumers. Will replace with aftermarket component, not Jeep's.

While driving vehicle started to make noise, consumer pulled over, and noticed a crack in manifold. Took vehicle to dealer,and they said it was ongoing problem since 1994. Consumer felt it was a manufacturer's defect.

On 10/09/00, while starting my vehicle I heard a noise coming from the engine compartment. I had the vehicle checked at the service station that has worked on my vehicle in the past. At that time I was advised that the exhaust manifold on my Jeep was missing some bolts. The mechanic advised me to contact a Jeep dealership because he had read that the bolts on the Jeep's exhaust manifold break. I then called a local Jeep dealership and advised them of the problem. They asked me how many miles my Jeep had on it and when I told him 83,000 miles, he told me that they only cover until 80,000 miles. If Jeep/Chrysler know this to be a problem with their Jeeps, something should be done for the consumer.

A crack in engine manifold. Manufacturer replaced the manifold at no cost to consumer.

Exhaust header developed a crack extending more than 80% of the diameter of the pipe. Crack occurred adjacent to the weld which holds the connection flange to the exhaust header. This piece has since been redesigned to correct this issue. Because the miles on the car (a little over 42,000) exceeded the warranty (by 6,000), it is my responsiblity for the costs of parts and labor. If Jeep has redesigned the part to keep the pipe from breaking shouldn't they re-imburse or fix those that had the original design flaw?.

The exhaust manifold cracked causing fumes to enter the car. Also the manifold supports the exhaust system which could fall off if crack would break completely. There must be an engineering design defect because the part has been redesigned. I also was told the used junk yard parts were cracked so I couldn't buy a used manifold. Not only the cost of the manifold but the safety issues with a failed manifold have me very concerned. Nlm.

Exhaust manifold weld cracked, carbon chemicals came inside of car.

Weld in pipe on manifold cracked. I don't think an exhaust manifold should fail at 52,000 miles. Dealer said there was an extended warranty on 4cy. Manifolds that were cracking but not 6 cyl. Dealer made me pay $200. 00 of the 750. 00 repair. I don't think I should ahve to pay for chryslers bad weld.

Consumers heard loud muffler noise. When vehicle was decelerating it would start to stall. Repair shop determined that it was a cracked exhaust manifold at a weld. Consumer contacted dealer. Vehicle was not under warranty.

Driving on a local road heard loud noises and noticed a crack in the exhaust manifold. Fumes/odor were getting into vehicle. Contacted dealer. Vehicle was no longer under warranty.

I have only included the one date I can remember that Jeep was in the repair shop. But, to this date, after Jeep warms up and then is shut off for approx 20 minutes, it hesitates on acceleration. Dealer said couldnt duplicate problem. Oil gauge dropped to zero, then engine knocked & I shut off. Dealer said oil pressure ok, could not duplicate prob. It still drops below 20 sometimes, but not zero again. I have had manifold bolts replaced twice and catalytic converter replaced once. Water leaks on passenger side & drivers seat belt gets caught in door latch.

Exhaust manifold started leaking around 30,000 mi. Now at 49,850 large cracks have developed. Vehicle misfires and runs rough. Jeep denies problem exists. Seems like the exhaust manifold should be covered under federal emissions warranty. Large number of similar complaints show obvious product defect.

The exhaust manifold had developed cracks & holes & had to be replaced. Had taken to mechanic & was informed a possiblity manifold was defective when it came from manufacturer.