Replacing Exhaust Donut Gasket
 

Fellow Jeepers,

I've been told by a trustworhy mechanic that I have a leaking donut
gasket where the exhaust manifold connects to the exhaust pipe headed
to the catalytic convertor on my 97 Sahara. The exhuast from the
catalytic convertor back is also shot. So, time for a new exhaust
system.

I've ordered the Banks Stinger Cat-Back system and purchased the donut
gasket from my local Jeep dealer. I couldn't spring for the Banks
Torque-Tube header just now, but plan on it down the road.

Anyone every changed the donut gasket without replacing the stock
exhaust manifold? I've found several posts about replacing the stock
manifold with a header, but haven't found any that talk about just
replacing the donut gasket. Am I in for a hard time? I've started
treating the bolts with penetrating oil. Is there anything else I
should do beforehand? Any advice from someone who has been down this
road would be appreciated.

Thanks in advance for your help and for all the entertaining and
informative posts.

Brad Fuqua
97 Sahara Edition

Re: Replacing Exhaust Donut Gasket
 

Brad Fuqua did pass the time by typing:

> Anyone every changed the donut gasket without replacing the stock
> exhaust manifold? I've found several posts about replacing the stock
> manifold with a header, but haven't found any that talk about just
> replacing the donut gasket. Am I in for a hard time? I've started
> treating the bolts with penetrating oil. Is there anything else I
> should do beforehand? Any advice from someone who has been down this
> road would be appreciated.

Three bolts (usually rusted). Air impact wrench works well but it
can be done with a breaker bar. Watch your knuckles. Plan where they
will go if the wrench cuts loose.

--
DougW

Re: Replacing Exhaust Donut Gasket
 

Brad Fuqua did pass the time by typing:

> Anyone every changed the donut gasket without replacing the stock
> exhaust manifold? I've found several posts about replacing the stock
> manifold with a header, but haven't found any that talk about just
> replacing the donut gasket. Am I in for a hard time? I've started
> treating the bolts with penetrating oil. Is there anything else I
> should do beforehand? Any advice from someone who has been down this
> road would be appreciated.

Three bolts (usually rusted). Air impact wrench works well but it
can be done with a breaker bar. Watch your knuckles. Plan where they
will go if the wrench cuts loose.

--
DougW

Re: Replacing Exhaust Donut Gasket
 

Brad Fuqua did pass the time by typing:

> Anyone every changed the donut gasket without replacing the stock
> exhaust manifold? I've found several posts about replacing the stock
> manifold with a header, but haven't found any that talk about just
> replacing the donut gasket. Am I in for a hard time? I've started
> treating the bolts with penetrating oil. Is there anything else I
> should do beforehand? Any advice from someone who has been down this
> road would be appreciated.

Three bolts (usually rusted). Air impact wrench works well but it
can be done with a breaker bar. Watch your knuckles. Plan where they
will go if the wrench cuts loose.

--
DougW

Re: Replacing Exhaust Donut Gasket
 

"DougW" <post.replies@invalid.address> wrote in message
news:h5hnb.33214$iq3.1322@okepread01...
> Brad Fuqua did pass the time by typing:
>
> > Anyone every changed the donut gasket without replacing the stock
> > exhaust manifold? I've found several posts about replacing the stock
> > manifold with a header, but haven't found any that talk about just
> > replacing the donut gasket. Am I in for a hard time? I've started
> > treating the bolts with penetrating oil. Is there anything else I
> > should do beforehand? Any advice from someone who has been down this
> > road would be appreciated.
>
> Three bolts (usually rusted). Air impact wrench works well but it
> can be done with a breaker bar. Watch your knuckles. Plan where they
> will go if the wrench cuts loose.
>
> --
> DougW
>
>

Just a note on penetrating oils. I'm not sure what you are using, but get a
can of PB Blaster if you don't have it already. This has got to be the best
stuff out there.

Chris

Re: Replacing Exhaust Donut Gasket
 

"DougW" <post.replies@invalid.address> wrote in message
news:h5hnb.33214$iq3.1322@okepread01...
> Brad Fuqua did pass the time by typing:
>
> > Anyone every changed the donut gasket without replacing the stock
> > exhaust manifold? I've found several posts about replacing the stock
> > manifold with a header, but haven't found any that talk about just
> > replacing the donut gasket. Am I in for a hard time? I've started
> > treating the bolts with penetrating oil. Is there anything else I
> > should do beforehand? Any advice from someone who has been down this
> > road would be appreciated.
>
> Three bolts (usually rusted). Air impact wrench works well but it
> can be done with a breaker bar. Watch your knuckles. Plan where they
> will go if the wrench cuts loose.
>
> --
> DougW
>
>

Just a note on penetrating oils. I'm not sure what you are using, but get a
can of PB Blaster if you don't have it already. This has got to be the best
stuff out there.

Chris

Re: Replacing Exhaust Donut Gasket
 

"DougW" <post.replies@invalid.address> wrote in message
news:h5hnb.33214$iq3.1322@okepread01...
> Brad Fuqua did pass the time by typing:
>
> > Anyone every changed the donut gasket without replacing the stock
> > exhaust manifold? I've found several posts about replacing the stock
> > manifold with a header, but haven't found any that talk about just
> > replacing the donut gasket. Am I in for a hard time? I've started
> > treating the bolts with penetrating oil. Is there anything else I
> > should do beforehand? Any advice from someone who has been down this
> > road would be appreciated.
>
> Three bolts (usually rusted). Air impact wrench works well but it
> can be done with a breaker bar. Watch your knuckles. Plan where they
> will go if the wrench cuts loose.
>
> --
> DougW
>
>

Just a note on penetrating oils. I'm not sure what you are using, but get a
can of PB Blaster if you don't have it already. This has got to be the best
stuff out there.

Chris

Re: Replacing Exhaust Donut Gasket
 

The bolts on the manifold / downpipe flange aren't nearly as bad as the
ones for the cat and muffler. I used Liquid wrench and alot of cursing
to get the manifold/pipe bolts on my '92 YJ off. I ended up using the
same technique plus a reciprocating saw to "remove" the muffler and cat.
As for the donut gasket, be careful. I ordered an OEM (hah)
replacement manifold that came with its own gasket and it wouldn't even
fit right!

Getting the old one off... I'd recommend attempting to twist the gasket
off rather than pry. There isn't a whole lot of room where that flange
is, and getting a pry-bar in there is going to be tough. Since it's a
97 you *might* be able to use a large screwdriver and pry it off by
twisting. If not, get some heavy duty gloves and a butane torch
(careful for wires) and try heating it up then twisting. Chances are
using a penetrant isn't going to help you as much as some heat will.
The good thing is that it's a throw-away part. If worst comes to worst
and you still want to do it yourself you can always Dremel it off.

The gasket needs to be pushed down onto the manifold flange prior to
bolting on the downpipe. If it doesn't fit right up to the manifold
flange then you need to either lube it up, get another one, or heat it
up with a torch and try again. I eventually gave up and had a local
muffler shop put a new gasket on and tighten everything down. Service
cost me about $15. Hopefully you shouldn't run into this since you
bought it from a dealer...

Finally, you might want to consider removing the exhaust pipe from the
cat to make working on the manifold/exhaust flange easier. If it's like
mine, there's a rubber insulator mounted on the transmission housing
that the cat plugs into via a bracket that bolts on with the exhaust
pipe. This means there's enough play in the pipe to move it a little
out of the way, but probably not enough to work on the gasket.

Best of luck!


Brad Fuqua wrote:

>Fellow Jeepers,
>
>I've been told by a trustworthy mechanic that I have a leaking donut
>gasket where the exhaust manifold connects to the exhaust pipe headed
>to the catalytic convertor on my 97 Sahara. The exhuast from the
>catalytic convertor back is also shot. So, time for a new exhaust
>system.
>
>I've ordered the Banks Stinger Cat-Back system and purchased the donut
>gasket from my local Jeep dealer. I couldn't spring for the Banks
>Torque-Tube header just now, but plan on it down the road.
>
>Anyone every changed the donut gasket without replacing the stock
>exhaust manifold? I've found several posts about replacing the stock
>manifold with a header, but haven't found any that talk about just
>replacing the donut gasket. Am I in for a hard time? I've started
>treating the bolts with penetrating oil. Is there anything else I
>should do beforehand? Any advice from someone who has been down this
>road would be appreciated.
>
>Thanks in advance for your help and for all the entertaining and
>informative posts.
>
>Brad Fuqua
>97 Sahara Edition
>
>

Re: Replacing Exhaust Donut Gasket
 

The bolts on the manifold / downpipe flange aren't nearly as bad as the
ones for the cat and muffler. I used Liquid wrench and alot of cursing
to get the manifold/pipe bolts on my '92 YJ off. I ended up using the
same technique plus a reciprocating saw to "remove" the muffler and cat.
As for the donut gasket, be careful. I ordered an OEM (hah)
replacement manifold that came with its own gasket and it wouldn't even
fit right!

Getting the old one off... I'd recommend attempting to twist the gasket
off rather than pry. There isn't a whole lot of room where that flange
is, and getting a pry-bar in there is going to be tough. Since it's a
97 you *might* be able to use a large screwdriver and pry it off by
twisting. If not, get some heavy duty gloves and a butane torch
(careful for wires) and try heating it up then twisting. Chances are
using a penetrant isn't going to help you as much as some heat will.
The good thing is that it's a throw-away part. If worst comes to worst
and you still want to do it yourself you can always Dremel it off.

The gasket needs to be pushed down onto the manifold flange prior to
bolting on the downpipe. If it doesn't fit right up to the manifold
flange then you need to either lube it up, get another one, or heat it
up with a torch and try again. I eventually gave up and had a local
muffler shop put a new gasket on and tighten everything down. Service
cost me about $15. Hopefully you shouldn't run into this since you
bought it from a dealer...

Finally, you might want to consider removing the exhaust pipe from the
cat to make working on the manifold/exhaust flange easier. If it's like
mine, there's a rubber insulator mounted on the transmission housing
that the cat plugs into via a bracket that bolts on with the exhaust
pipe. This means there's enough play in the pipe to move it a little
out of the way, but probably not enough to work on the gasket.

Best of luck!


Brad Fuqua wrote:

>Fellow Jeepers,
>
>I've been told by a trustworthy mechanic that I have a leaking donut
>gasket where the exhaust manifold connects to the exhaust pipe headed
>to the catalytic convertor on my 97 Sahara. The exhuast from the
>catalytic convertor back is also shot. So, time for a new exhaust
>system.
>
>I've ordered the Banks Stinger Cat-Back system and purchased the donut
>gasket from my local Jeep dealer. I couldn't spring for the Banks
>Torque-Tube header just now, but plan on it down the road.
>
>Anyone every changed the donut gasket without replacing the stock
>exhaust manifold? I've found several posts about replacing the stock
>manifold with a header, but haven't found any that talk about just
>replacing the donut gasket. Am I in for a hard time? I've started
>treating the bolts with penetrating oil. Is there anything else I
>should do beforehand? Any advice from someone who has been down this
>road would be appreciated.
>
>Thanks in advance for your help and for all the entertaining and
>informative posts.
>
>Brad Fuqua
>97 Sahara Edition
>
>

Re: Replacing Exhaust Donut Gasket
 

The bolts on the manifold / downpipe flange aren't nearly as bad as the
ones for the cat and muffler. I used Liquid wrench and alot of cursing
to get the manifold/pipe bolts on my '92 YJ off. I ended up using the
same technique plus a reciprocating saw to "remove" the muffler and cat.
As for the donut gasket, be careful. I ordered an OEM (hah)
replacement manifold that came with its own gasket and it wouldn't even
fit right!

Getting the old one off... I'd recommend attempting to twist the gasket
off rather than pry. There isn't a whole lot of room where that flange
is, and getting a pry-bar in there is going to be tough. Since it's a
97 you *might* be able to use a large screwdriver and pry it off by
twisting. If not, get some heavy duty gloves and a butane torch
(careful for wires) and try heating it up then twisting. Chances are
using a penetrant isn't going to help you as much as some heat will.
The good thing is that it's a throw-away part. If worst comes to worst
and you still want to do it yourself you can always Dremel it off.

The gasket needs to be pushed down onto the manifold flange prior to
bolting on the downpipe. If it doesn't fit right up to the manifold
flange then you need to either lube it up, get another one, or heat it
up with a torch and try again. I eventually gave up and had a local
muffler shop put a new gasket on and tighten everything down. Service
cost me about $15. Hopefully you shouldn't run into this since you
bought it from a dealer...

Finally, you might want to consider removing the exhaust pipe from the
cat to make working on the manifold/exhaust flange easier. If it's like
mine, there's a rubber insulator mounted on the transmission housing
that the cat plugs into via a bracket that bolts on with the exhaust
pipe. This means there's enough play in the pipe to move it a little
out of the way, but probably not enough to work on the gasket.

Best of luck!


Brad Fuqua wrote:

>Fellow Jeepers,
>
>I've been told by a trustworthy mechanic that I have a leaking donut
>gasket where the exhaust manifold connects to the exhaust pipe headed
>to the catalytic convertor on my 97 Sahara. The exhuast from the
>catalytic convertor back is also shot. So, time for a new exhaust
>system.
>
>I've ordered the Banks Stinger Cat-Back system and purchased the donut
>gasket from my local Jeep dealer. I couldn't spring for the Banks
>Torque-Tube header just now, but plan on it down the road.
>
>Anyone every changed the donut gasket without replacing the stock
>exhaust manifold? I've found several posts about replacing the stock
>manifold with a header, but haven't found any that talk about just
>replacing the donut gasket. Am I in for a hard time? I've started
>treating the bolts with penetrating oil. Is there anything else I
>should do beforehand? Any advice from someone who has been down this
>road would be appreciated.
>
>Thanks in advance for your help and for all the entertaining and
>informative posts.
>
>Brad Fuqua
>97 Sahara Edition
>
>