Manifold/header/muffler/tail Pipe Problems of Jeep Wrangler - part 2

How do you convince an automaker to do a recall? do you have to file a class action suit? if you go out to your parking lot and look at almost any Jeep Wrangler, 4 cylinder engine, you will see that the front bolt for the exhaust manifold is broken off. This will often lead to exhaust leaks and may cause the vehicle to fail a safety inspection. The head mechanic at the Jeep dealership told me that all Wrangler 4 cylinders do this. He went on to say that he has done a hundred of them. The dealer ship wants hundreds of dollars to fix this. I have asked around at other auto repair shops and the cost is not that much less. If all Wrangler 4 cyls do this, and it is a safety issue, why isn't it a recall issue? mica calfee flower mound, texas.

See all problems of the 2001 Jeep Wrangler 🔎.

Cracked manifold.

See all problems of the 1999 Jeep Wrangler 🔎.

Main exhaust header flange at the collector cracked leading to exhaust gases entering the car.

See all problems of the 1998 Jeep Wrangler 🔎.

Found crack in exhaust manifold between the #1 and #2 ports at around 68,000 miles, after discussing this problem with a number of other Jeep owners I learned this is a common problem with the 1999 and other years back. My complaint is, if daimler Chrysler is aware of this problem and I am sure they are, why aren't they addressing it. Unhappy with dealer and stock manifold, replaced with after market exhaust manifold header.

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!.

See all problems of the 1997 Jeep Wrangler 🔎.

I took my Jeep to chuck nash Jeep because of a popping sound. They said the exhaust mainfold was cracked, and told me it would be $750. 00 to replace, I refused the repair, they charged me $75. 00 for the evaluation.

Heard excessive noise coming from engine. Investigation revealed that the exhaust header was cracked at the exhaust flange connecting the crossover pipe to the manifold.

I have a 1999 Jeep Wrangler which was manufactured in oct of 1998. My oem exhaust manifold had two cracks in it as of December of 2003, with the milage on the vehicle being roughly 42000. I replaced the manifold with an aftermarket manifold purchased from o'reilly auto parts in springfield, mo. Eleven months later, the aftermarket manifold cracked also. There is too much heat and pressure in the 4. 0 engine for the manifolds to be able to handle, causing failure. Jeep dealerships replace hundreds daily, and are well aware of the engine problem, but also that the stock manifolds are made out of weak materials. Any muffler shop or tech will agree with this, as did 8 Jeep engineers at camp Jeep. I am currently going on my 3rd, and plan on changing to either a borla or banks header to try to solve the problem. Headman hedders has discontinued making a replacement for the Jeeps because they aren't able to solve the problem, and borla agrees, but continues to warranty exchange those that come back cracked. The exhaust leaks penetrate the cab and can cause headaches and drowsiness after long periods of exposure. Gas milage is greatly reduced by this issue. I am looking for reimbursement of my aftermarket header if Jeep is unable to correct the issue or recall the manifolds.

1)the vehicle failed the annual inspection - and I was advised the reason was "exhaust manifold". 2)I called the dealer - who thought my vehicle was a "2. 5" which already has a recall on the exhaust manifold, but I have a "4. 0" which currently does not. I asked what harm is being done if I do not get it fixed - and was advised that since there is a hole in the exhaust manifold, exhaust fumes are filling the cab (like the 2. 5). I was at that time advised that there is no recall on this part. As it was explained to me, the part on the 2. 5 is a bolt that attaches to the motor, and when it breaks, leaks exhaust into the cab; and on the 4. 0 (which I believe is also a common problem), that there is a break in the base of the "y" pipe, which also leaks exhaust into the cab. I called the manufacturer customer line 800. 992. 1997, I advised that I was aware that this was a serious problem, and that there is already a recall on a similar model; I was told that all they could do was "register the complaint". I asked "how does one go about a recall process" and was told it was involved and complicated, and I was directed to this site after pressing for satisfaction. I then asked "how many people have to die before you recall this part?", and the rep on the other end of the line giggled. I went on to ask that if there was a recall on this part would I be reimbursed for my expenditure, and I was advised that "yes", I would be reimbursed for having to pay for this repair. 3)because it is a dangerous condition, I am having the exhaust manifold replaced. I can make it available for inspection.

Every manifold in Jeep Wranglers are faulty and crack leaving the cabins of Wranglers filling with carbon monoxide. This is a well known issues with Jeep Wranglers where the manifold is made with iron that does not expand and the welsing is sub par allowing for cracks which leak carbon monoxide.

Manifold cracking on 1999 Jeep Wrangler, causing rough running condition and fumes inside cabin.

Intake manifold cracked.

I love my 1999 Jeep Wrangler and have been very happy till now. My husband and I have owned many new cars over the years and this is the first time either one have heard of an exhaust manifold going bad. When having the manifold replaced we were told it has been redesigned and is different than the one replaced. It had cracked in several places, mainly at the welds. I fill since I never take it off road that this should not of happen. Not to mention it was very costly. I fill since this is a manufacturer problem I should be reversed for something like this.

Experianced headaches, nausea, as well as audible knocking from under hood. My 1999 4. 0 liter 6 cylinder was found to have broken exhaust manifold, leaking hot gasses and exhaust into engine compartment and passenger compartment. Dealership aware that there is problem with manifold, as have redesigned it and replacement cost in excess of $500. 00 contacted Chrysler and filed complaint, told they area aware of problem, but will not stand behind it or issue recall. Local exhaust shop advised they do several per month with this defective exhaust manifold, both Wrangler and cherokee between 1996 and 2000 model year. Exhaust was revised in 2000 because of problems, but Chrysler will not stand behind product denying the problem is a defect. Chyrsler should warranty this problem as they did with the 2. 5 liter. Milage at time was only 39,000 when cracked.

1998 4. 0 Jeep Wrangler (49k mi) with cracked exhaust manifold. Have replaced manifold twice, once with oem and the last time with banks header w/lifetime guaranty. Most 4. 0 I know have had to replace the header within the first 100k mi. Design sucks. . .

Exhaust manifold cracked in 3 places. The first manifold was replaced by dealer at approximately 35,000 miles. Second manifold is cracked. This seems to be a common defect with Jeep Wrangler 4. 0l years 1997-1998.

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.

Paint peeling off of fenders and on the hindges of the hard top and doors. There is a constant ticking, rattle sound coming from the engine. I have driven with the head mechanic,and the dept. Manager. They both have heard the sound. The Jeep has been in the shop "9" times and the problem still exhists. I have loss confidence in the local dealership's service dept.

See all problems of the 2003 Jeep Wrangler 🔎.

1999 Jeep Wrangler 6 cycl. Has been to the dealership on multiple visits. Loss of power during highway driving. After replacing the fuel pump, radiator, and performing an additional tune-up but problem is still unresolved. Now find that there is a crack in the intake manifold and the exhaust manifold has completely cracked.

First heard a problem with the exhaust system just prior to the easter holiday 2002 and took it to the dealership to be investigated after the holiday weekend. I was told the was a crack in the exhaust manifold and the vehicle was one day out of warranty (due to the holiday weekend). After considerable debate, the dealership agreed to repair the vehicle for a $150. 00 deductible. Now a year and a half later the exact same issue has arisen and the factory repair is only warranted for 12 months/12,000 miles. After an exchange of 4 emails with daimler/Chrysler they continue to tell me there is nothing they can do and I am liable for the full repair cost.

The exhaust manifold headers have cracked in two separate locations. The first crack is located at a bend in the header and the second crack is near the weld at the flange where it connects to the exhaust pipe. This location has cracked completely around the pipe, mostly at the weld but upwards 1/2" into the manifold itself.

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.

Exhaust manifold leak.

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.

The exhaust manifold cracked in three different places and caused the vehicle to misfire and stall. An independent shop stated that the manifold cracked because it was not properly supported. The dealer was notified but stated there was nothing they could do.

Chrysler originally offered to reimburse ferry fare required to take car in for a safety recall. I have submitted receipts and Chrysler has now refused to make the reimbursement. Chrysler's reference code is 11552946.

See all problems of the 2002 Jeep Wrangler 🔎.

Exhaust manifold cracked in two places. Poor design due to the inability to expand and contract due to thermal expansion (in an exhaust manifold!!!). Exhaust fumes entering cabin while driving.

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.

I was forced to get a new exhaust manifold for my Jeep at 76,000 miles. The dealer's price was $1,300 for the repair. I've seen all over the internet and on the NHTSA's site that this is a common problem. I've been told by mechanics that the Jeep's manifold is a lesser quality. I lodged a complaint with customer service who called the dealership and, after talking with the service tech, said that he couldn't do anything because it wasn't a "defect" but rather "normal wear and tear. " I' can't believe this is true after seeing this common problem!!! Chrysler -- why is this not a factory recall?.

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.

Small crack developed in exhust manifold, causing ticking noise and lowered fuel economy.

I have had numerous problems with my Jeep Wrangler 1998. This is a partial list I sent to Chrysler: I bought my Jeep with just 3600 miles on it from a dealer in 1999. From day one I started experiencing problems. Many of them I returned to the service department. Some they were able to fix, others, after many return trips, they were 'unable to duplicate the problem'. 1. Gauges would stop working while driving - I brought the vehicle in 5 times before they were able to duplicate and finally fix the problem. 2. This was also true of the blinkers that not always worked - or worked all at the same time. 3. My hazards still do not work every time. 4. The air conditioner goes out when driving,very uncomfortable when it is hot and raining. 5. The sound bar has never worked properly - first it would only come in some times - now never. 6. Headers are cracked - bad. They have been welded several times. When I went to have them welded it was found they were welded before my purchase - at 3600 mil! they are still cracked, welding does not hold. I can not get anyone to replace them because even exhaust specialists say it is too cumbersome. The dealer charges way more than I have considering the number of repairs and the price of gas - at 12 mpg. 7. Drivers seat belt locks tightly with any amount of pressure on the brakes - it has now gotten to the point it locks just while driving. 8. Windows - the zippers broke almost immediately - I paid alot to have these replaced. The back window now has a cut in it and is very difficult to see through. 9. The top has never quite fit right; it has always leaked and been extremely noisy - more so than anyone else's that I know. It has also come apart at the seams. The dealership has not been of any help. They wanted to charge outrageous amounts just for diagnostics, even when I had the best warranty. I've also had problems with the door molding coming out immediately, grinding in the steering wheel, grinding while trying to put it in reverse and more.

Heard loud noises coming from the engine. Check engine light came on. The manifold was cracked in two places. The area dealers happen to have the newly designed manifold in stock due to the problems with the manifold cracking. Have spoken with several people and the same problem occurred with them. This should definitely be recalled. The new manifold has springs built in to make room for give -- the old one did not, therefore causing them to crack. It is very unsafe and costs a lot to get it fixed.