Build Thread Starting from the frame 1977 CJ5

[Jeep Soup]

OK,
This is what I was talking about.
A second (2 piece) Gasket for the intake Runners. (The Blue One)

JUST LEAVE IT ALONE!
until you Get a Leak !!!
If you do get one later. I and others will help you with replacing it with as little Compound Cussing as required.

It's best to get one of your "Beer Buddy's" to help too.


Just to note, the Grey one is pictured upside down.

 

[Serdich77CJ5]

Help suggestions on how to get exhaust off? Are those bolts replaceable can I cut them?

 

[Sawjaws]

They are studs, so if you cut them you'll have to drill out and re-tap what's not cut off, which is a can of worms.

Start with heat. Plenty of heat. Get it glowing, let it cool for a bit until the glow disappears, but it's still really hot and then use an impact of you have it.

 

[Jeep Soup]

Yep,
What Sawjaws said. I helps if you soak them with penetrating oil for a Day First (Let them soak overnight)
Then when you hit them with a Torch, it will chase into the Threads.
A second approach is if you have room, just Cut the Nuts enough to "Pop Them" open with a Chisel.
Once everything is apart. Clean up the stud threads.

 

[Serdich77CJ5]

It's really tight I don't think I can get the cut off wheel in there. This is going to be fun. ha ha

 

[Black Thumb]

Sometimes a cutoff wheel on a die grinder or a dremmel will get you in places an angle grinder won’t go.

 

[Sawjaws]

If you're going to try to cut through just the nuts, they actually make nut breaker tools you can buy online or at most local auto stores. It might also be tough to fit in there, but it's something to look into maybe.

 

[Serdich77CJ5]

I hated to do it, but I had to take the banner fold off because I could not get those bolts loose so I had to cut them and drill them

 

[Serdich77CJ5]

In a way I’m glad I had to take the manifold off every single one of those bolts was just finger tight and they’re so buildup all around the exhaust manifold

 

[Serdich77CJ5]

For some reason I can’t attach pics will try again later. There was leaking around two of the ports from the exhaust

 

[Serdich77CJ5]

I am also pretty sure that engine is not the engine that was with the Jeep when it was built. Is there a difference between the years on the AMC 258 i6 / 4.2l engines? or are they all pretty much the same?

 

[CJ]

I am also pretty sure that engine is not the engine that was with the Jeep when it was built. Is there a difference between the years on the amc 258 engines? or are they all pretty much the same?

All 258s are exactly the same by physical dimensions.

 

[Serdich77CJ5]

I thought so just want to be sure.

 

[Jeep Soup]

Good Morning
Well now that you have the manifold off,
A Smart Trail Driver will strip the manifold.
BUT Do Not separate the Intake from the Exhaust
Unless you can See an Actual Leak at the meeting joint.
Take it to a local Engine Machine Shop and have it “Faced”
That you have a nice flat match mating surface.

Just a little heads up for your next project……
A Sawzall sometimes can reach in and cut the nut at
an angle. Then you can Strike the cut with a Chisel to crack it.
And you don’t have to hit it straight on. You can catch the cut
Edge and hit it in the Direction of turning off.
Also you can add torch heat as you now have “Opened Up”
the nut. Heat will expand the Nut, and heat will get at the threads too
Help get it off.

 

[Serdich77CJ5]

Good morning Soup.

Once I got the intake off I was able to take a good look at the studs. There was no way I was getting the nuts off. There were no threads left rusted gone. Had to cut and drill them out. Sucks I know.

I saw a good build up of soot between the intake and exhaust. Would show you a picture but for some reason I can’t attach any.

 

[Jeep Soup]

No worries
Just a Suggestion on pix,
Your Firewall may be the culprit.
Try when you sign onto this site,
Choose the "Reject Optional Cookies" icon. Then enter your regular site name and password.
See if that works.

 

[Serdich77CJ5]

What I’m having trouble sourcing is the tailpipe from the manifold to the cat. Can’t find one anywhere

 

[CJ]

What I’m having trouble sourcing is the tailpipe from the manifold to the cat. Can’t find one anywhere

1977 Jeeps do not have many aftermarket parts especially exhaust... Just take it to a shop who specializes in older vehicles. They are everywhere...

 

[Black Thumb]

I’d just go to a muffler shop with a bender and have them eyeball it. Probably cheaper than a preformed OEM anyway.

 

[CJ]

Yep, there are no preformed pipes anyway...