Installing One On The 1999 Jeep Wrangler TJ
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The earlier TJ's - up until about 2001 - tend to develop one or more cracks in the exhaust manifold before the end of 5 years. It's a problem in the design that just about every TJ will have. This results in a very loud engine, can affect your fuel economy, and may keep your vehicle from passing emissions tests. Of course, the factory did not admit that it is a defect, and it is not covered under warranty. If Daimler-Chrysler would have confessed this and made good on it, it would have removed a big blot on an otherwise excellent vehicle experience.
The exhaust manifold is important. Around here, the emissions test is performed by plugging a tester into the OBDII port. As long as your check engine light isn't on you should pass with no difficulties. However, a cracked manifold is loud and there are usually rules telling the inspection station that they should not pass it if it has anything that is clearly broken. You may find someone that will look the other way - especially since this usually won't trip the OBDII - but it is better to have your Jeep performing 100%.
Many guys remove and re-weld them. If you are going to go to the trouble of removing it, you might as well replace it since they usually crack again. There are a number of options out there. The factory has a new replacement, and there are a ton of replacement manifolds from various outfits such as Crown or knock-offs on E-bay. These are somewhat better as they have flexible joints, but some of the welds we saw on units on display at SEMA last year were not very good. The way we look at it, if you are going to do something, do it right the first time. Just like in the rest of life - you get what you pay for.
While at SEMA, we took some time to speak with the folks at Gale Banks Engineering. They have a complete replacement exhaust manifold made from 409 stainless steel and a matching cat-back (everything that is in back of the catalytic converter) exhaust system called the Monster Exhaust. I could tell that they have their stuff squared away. They really knew what they were talking about and had test results to back it up. Their exhaust manifold - which they call a TorqueTube - was one of the most solid pieces of work I have seen.
To be honest, I am not at all into chrome and stainless steel on a Jeep. However, we are into systems that will last. I once owned a Saturn, and the best thing on it was the stainless steel exhaust. It lasted longer than the rest of the vehicle. I'm strongly in favor of stainless steel when it comes to exhaust systems.
When I compared the TorqueTube and their Monster Exhaust to the other aftermarket products out there - even Borla - it was clear that Banks puts a lot of time and effort into the design of their products, and into making them. The TorqueTube has a truly flat flange which is welded inside and out, and they supply a gasket made from SMI 900 which has excellent heat resistant characteristics. The system is also C.A.R.B. EO certified and includes the appropriate labels.
We made arrangements to obtain a unit to test. They even offered to send their Monster Exhaust system - complete with muffler. We took them up on it, and I am glad we did. It turned out to be prefect timing.
I did have two qualms about installing such a nice exhaust system. First is that when we are out rock crawling, we might dent or ding something. On a recent trip to Constrictor we banged the tip of the exhaust pipe and put a pretty good dent in it. How will the Banks system hold up to this? It was so nice and shiny, I almost didn't want to find out.
The other was relating to the future, re-evaluating and upgrading the lift. My dream lift would be something like a Teraflex 4" LCG lift with belly-up skidplate. The problem is that the LCG kit somewhat limits you on exhaust options (Teraflex recommends a Magnaflow 10416 4" round with 2.5" connections with that kit). But it was worth it for now to install the Banks Monster Exhaust and see how it performs, and worry about the future later.
You don't have to install the complete system - you can install only the TorqueTube Exhaust Manifold if you want. The great thing is that the system is all direct bolt-on replacement. You don't have to drill any holes or weld anything. That makes it much more appealing. I am not a person you want welding anything. One of our Associate Editors (Jerry Pace) is a wiz with all things to be welded, but he was not available when this installation was taking place.
To start the replacement of the Exhaust Manifold, you need to take a bunch of stuff off of the top of the engine - the fuel rail, cables off of the throttle body, etc. This is not for the faint of heart, but it isn't rocket science either. You just need to be able to think clearly and follow directions. The manuals which come with both the TorqueTube and the Exhaust are excellent. You can download them using the links below. Between those and the Factory Service Manual you can figure it out very easily. But it does take a few tools to perform this job - a couple of which we did not have available to us at the time. As a result, we made arrangements with the local dealership (Doug Smith in American Fork, UT) to have them perform the labor. They were very cooperative, and did a great job.
Here are some photos to show you the state of the original manifold. You can see clear through some of the cracks.
That is just a crappy design. We were glad to have it out of there. Now let's look at a real exhaust manifold.
Compare The Photo Above
With the OEM Hardware In The Next Photo
As you can see, this is one superior piece of hardware. Those welds are on both sides with the extra weld at the stress points. There is a lot of machine work that goes into the TorqueTube, and you are getting what you pay for.
The installation took almost 4 hours at Doug Smith. They really did a nice a job, and they commented that it was the best aftermarket manifold they had seen. They have seen a lot of the cheaper ones and some of the other big name systems. It beat the heck out of the new factory replacement, too.
The tech installing it said that the Jeep still would not pass inspection because the muffler was broken. Fortunately we had the Monster Exhaust back at the base. We let him know that was the next step after we left. He had seen the Monster Exhaust before and told us he thought that was a great choice.
So it was back to the office to install the Banks Monster Exhaust.
This is a complete package with everything you need. It is 100% bolt on, and you don't need the specialized tools you need to replace the exhaust manifold. The manual is very complete, and this installation is relatively straightforward. The package comes complete with the muffler, exhaust pipe, chrome tip, and the clamps to mount everything. As long as you can handle a wrench or socket driver - and have a can of WD-40 - you will be all set. At least, to install this kit.
Removing the factory setup presented some challenges.
The factory muffler was indeed broken. The muffler housing separated from the pipe inside of the muffler. That pipe was stuck - hard - onto the catalytic converter pipe. It was not just a matter of sliding it off. We ended up cutting off the factory tailpipe and the muffler housing slid off, leaving the pipe stuck to the pipe from the catalytic converter.
We had get it off of the catalytic converter but we didn't want to cut the pipe coming off of the cat, so we had to be careful. We ended up using a Dremel and a heavy duty cutting wheel to make a slit in the muffler pipe that would allow it to expand - all without cutting the catalytic converter pipe that was slid under it. Once that was done we used a plumbers wrench to turn the muffler pipe to get it to come off. It ended up taking a lot more time than we had allocated to the task, and we didn't get any photos of that fiasco. We did get some photos of the original muffler, and some with the new Banks unit next to it.
And A Look Down Inside The Muffler
But with that behind us, we were prepared to install the brand new Banks system.
Starting with the muffler, slide the inlet pipe on the muffler over the pipe coming from the catalytic converter. Remember to put the clamp on before connecting them, but don't tighten it yet.
The next step is the exhaust pipe. Note how it compares to the factory pipe. It looks like Banks can say "Quality is Job 1" and mean it.
It takes a bit of work to route it in, but it goes in pretty easily. You want to get it into position - again with the clamp position but not tightened - then get the hangers put in.
The hangers are pressed into the rubber joints, and you will find the job much easier if you hit them with WD-40. This was the hardest part of the entire installation. Those rubber joints on the hangers are a bit tight.
After the hangers are in place and the pipes are positioned, tighten the clamps and put on the exhaust tip. It is a press fit with a clamp you tighten down. It looks VERY good, but I was a bit concerned about wheeling with it. Only time would tell how it would hold up.
We put a bit of high-temp RTV around the joints as well as a bit of extra insurance. We don't want any leaks popping up if we can avoid them.
We have now been running the system for about 9 months and it has performed very well. The sound from the Banks system is deeper and bit more "intimidating" without being obnoxious. Most of the other guys we wheel with really like it. That was not our primary purpose in installing it, but it is a bit of a side benefit.
I do feel like we picked up a little power and fuel economy, but by itself it was not enough to write home about. After installing the Banks TorqueTube, Cat-Back Exhaust, and the ARB Snorkel, we did pick up some fuel economy - but it took all of these together to make any real difference, and that was only a couple of MPG. But with fuel prices as they are, it has been a welcome addition. Any little bit can help.
The best thing about the TorqueTube Manifold and the Cat-Back Exhaust is that they have served as a durable replacement for the factory parts. I don't foresee any problems with them, but we may have to re-evaluate the Cat-Back when we finalize the lift kit. Many of these necessitate changes to the exhaust, so we will have to see.
And before I forget, how did that chrome exhaust tip hold up? After a lot of wheeling - Moab and elsewhere - there is a dent. Not a bad dent, but it does not look exactly like it did from the factory. Then again, this isn't just a show Jeep - it is on the road every day and on the trail frequently. That's just part of life.
If you want to get a solid replacement for your factory exhaust manifold or your exhaust system, look no further than Banks Engineering.
For more information, contact:
Gale Banks Engineering
546 Duggan Avenue
Azusa, CA 91702
626-969-9600 Voice
626-334-1743 FAX
-- James Bell Jr.
Click HERE For The TorqueTube Installation Instructions
Click HERE For The Monster Exhaust Installation Instructions