I'm going to replace the exhaust pipe on my '89 YJ 4.2. I was told the only way to get the nuts off is with a torch. i.e.. Heat them to cherry red and then try to get them off. Will the studs be useable after this or must I replace them also. Also, there is NO gasket between the exhaust pipe and manifold, correct? Thanks, Joe
Joe C did pass the time by typing:
Depends on the connection. I'm talking from my ZJ here but your exhaust header should be similar.
Between the exhaust pipe and manifold there is usually a lead o-ring V shaped thingy. That should be replaced. The bolts are usually so buggered up from heat that a angle grinder is the easier way to get them off. I got mine off the 93ZJ with a long extension and a breaker bar. The rest of the exhaust came out with an angle grinder and strap-pipecutter.
Start first by blasting all the bolts with PB-Blaster then wait a day before cranking on them.
You can soak the nuts in a good penetrating oil. I recommend a couple days of many soaks.
I then try a 6 sided deep socket on them first. Do not use a 12 point socket or you will round them off. This 'might' work depending on their shape. If not, then it is torch time. I recommend you go after the stud/manifold junction just to save farting around. If you have to torch the nuts, 99% the studs will not be reusable, but there always is that 1%...
New stud and brass nut kits are sold at most auto parts stores and are not expensive.
The 'newer' 4.2 manifold does not use a gasket. Some of the 1st generation did.
Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 88 Cherokee 235 BFG AT's Canadian Off Road Trips Photos: N>With a torch, heat the nuts 'til they're cherry red, and turn 'em off.
To remove studs, heat the area around the stud, but not directly the stud, and turn it out.
Spdloader
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