exhaust manifold stud measurement

[mjeff87]

This is for the 2.5 on my TJ, but they're all the same anyway..... :D

 

anyone know offhand the size/pitch (at least for the side that screws into the head) and length of the exhaust manifold studs on a 2.5/4.0? I need to fix the rear one on my TJ next week to get a safety sticker on it, and need to pick up a replacement.

 

TIA,

 

Jeff

[dasbulliwagen]

Youll need a front one too when you go to do the job, it will break when you try to pull it out. Chrysler had a TSB on them. I did the job recently on a wrangler, wasnt too bad.... I just went and found it... see below. Drill your old studs out, install the new ones, a new intake/exhaust gasket, set the manifold on, put the spacers on the stud before the washer and nut and tighten the spacer down into the manifold stud hole, and to the proper torque. Good luck. I need to do this same thing to mine, but it really isnt leaking, so I'm in no hurry.

 

 

NO: 11-07-98 Rev. A

SUBJECT: Outer Exhaust Manifold Studs Breaking

DATE: Dec. 11, 1998

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-07-98, DATED JUL. 31, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODEL YEARS, CLEAN POINTS, AND NEW PARTS.

 

NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE **(SALES CODE EPE)** BUILT PRIOR TO DEC. 7, 1998 (MDH 1207XX).

 

SYMPTOM/CONDITION:

The outer exhaust manifold studs may fatigue and break (Figure 1).

 

DIAGNOSIS:

Inspect either manifold stud for breakage. If breakage is noted, perform the Repair Procedure.

 

PARTS REQUIRED:

Qty Part No. Description

**2 06036193AA Stud, Exhaust Manifold**

**2 06036221AA Washer, Flat**

**2 06036171AA Nut & Washer**

2 33003332 Spacer

1 53020112 Gasket, Intake

 

 

REPAIR PROCEDURE:

This bulletin involves replacing both outer mounting studs, clamps, and nuts **with new parts** and tightening the outer studs to a reduced torque of **20 Nm (180 in. lbs.)**.

 

Remove the intake/exhaust manifold per service manual procedures to gain access to the broken stud(s).

Remove the outer studs from the cylinder head. Use a stud removal tool if possible or drill the broken stud from the head.

Install two new outer studs p/n 06036193AA into the cylinder block. **Torque the studs to 14 Nm (126 in. lbs.)**.

Clean any carbon deposits or debris from the exhaust manifold.

Reinstall the exhaust manifold. **Use only the new parts listed above to attach the outer ends (Figure 2).**

Torque the bolts in the order and specification as listed in Figure 2.

**NOTE: THE TORQUE SPECIFICATION FOR THE OUTER EXHAUST MANIFOLD STUDS HAVE BEEN REDUCED TO 20 NM (180 IN. LBS.)**.

 

POLICY:

Reimbursable within the provisions of the warranty.

 

TIME ALLOWANCE:

Labor Op. No. Time

09-45-01-92 2.0 Hrs.

 

 

FAILURE CODE:

Code Description

P8 New Part

[mjeff87]

yeah, I'm gonna replace both of them while I'm in there.

 

For search purposes, the studs are 3/16-16_3/16-24 X 1 3/4"

 

Picked up 2 new ones today at NAPA.

 

Then drove 30 minutes to get the only head bolt set I could find in stock anywhere :fs1:

 

Had to buy a deep well 1/2" drive, 12 point 1/2" socket and drill out the inside so it will slip over the tops of the 4 long head bolts.

 

I haven't even started the job yet and am already tired...

 

Jeff