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  #1  
Old 12-08-2015, 01:29 PM
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4.0L Exhaust header

While under my '99 GC last night doing an R/R brake caliper & hose, I noticed I have a small hole rusted in the header pipe, right in the middle of a bend (where the exhaust moves from the left side to the right side of the car). There appears to have been 2 little tabs of some type that had something clamped onto them. Could these have been ground straps? What ever they were, they are rusted off now with only the tabs which were welded to the exhaust pipe. Moisture has gotten between the little tabs & the pipe & allowed it to rust thru. It appears I'll have to weld a patch on, because it looks like the entire exhaust header is welded up as one big assembly.

Anyone else have this issue? If this really was a ground strap, does it really need to be there? I could not find an attachment point on the body anywhere that this would have gone to.
thanks,
Mike S

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Old 12-20-2015, 02:43 PM
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I have the same exact issue! Looks like something was once there, but it's long gone now. I just planned on using some of that putty stuff at the auto parts store to seal it up
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Old 12-20-2015, 10:18 PM
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Re: 4.0L Exhaust header

I'm afraid that the hole is too close to the engine & the extra heat will be too much for a glue patch.

During the Christmas break I plan t weld a patch on mine. I just hope when I take the grinder to it to clean it up the hole doesn't get too big.
Mike S
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Old 12-28-2015, 09:43 PM
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Re: 4.0L Exhaust header

Actually, the pipe in question is not a "header". It is part of the catalytic converter assembly or just the front pipe that is attached to the the exhaust manifold. My WJ has the same tabs and I too have wondered over the years about the purpose. None of the photos that I have come across regarding the exhaust system show anything attached there, and it is fairly unlikely that, at this point, we will ever find a jeep with what ever was there still attached.
something to make you go HMMMM
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Old 01-03-2016, 09:47 AM
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Re: 4.0L Exhaust header

Finally got around to fixing the pipe yesterday. The holes weren't as bad as I had feared. I used a contour gage to find a close match of the curvature from my pile of old NOS Rambler exhaust header pipes & cut out a patch.

It's best to remove the front drive shaft to get more access with the welder. I found out that you have to unbolt the back end of the drive shaft first before you can remove the front joint. The welding went well except for one spot where I burnt thru & had to fix.
Mike S
Attached Images
File Type: jpg Exhaust Pipe 1.jpg (22.3 KB, 4 views)
File Type: jpg Exhaust Pipe 2.jpg (22.2 KB, 4 views)
File Type: jpg Exhaust Pipe 3.jpg (31.4 KB, 2 views)
File Type: jpg Exhaust Pipe 4.jpg (19.5 KB, 4 views)
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