Exhaust Manifold - Outer Studs Breaking

NO: 11-07-98 Rev. A

GROUP: Exhaust

DATE: Dec. 11, 1998

SUBJECT:
Outer Exhaust Manifold
Studs Breaking

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.

MODELS:

**1996 - 1999** (AN) Dakota
1991 - 1992 (MJ) Comanche
**1997 - 1999** (TJ) Wrangler
**1991 - 1999** (XJ) Cherokee
1991 - 1995 (YJ) Wrangler

NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5 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:

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.)**.

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

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

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

4. Clean any carbon deposits or debris from the exhaust manifold.





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

5. 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 Operation No: 09-45-01-92 2.0 Hrs.

FAILURE CODE: P8 - New Part