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Discussion Starter #1
Today I went out to start the Jeep, and let it warm
up for about 5 minutes. When I came out, I could hear
the distinct sound of an exhaust leak! When I opend
the door I could smell fumes in the cab. (8 days old to me)
Warranty only covers internal engine parts.

Took it in today, and they said the exhaust bolts were broken.
Huh? I have a 1999 XJ with the original bolts! Anyway, I ended
up buying an extended warranty plan, and they agreed to fix it
for free. Otherwise would have been $425 out of pocket.

At least I have a 3 year warranty now, so if anything else breaks
it's covered. I figure with an 06 that has 67k, a lot can still go wrong.....

I've never heard of exhaust manifold bolts breaking for no good reason.
 

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If they were screwing with it, it was because they were trying to fix the exhaust leak it had and they thought tightening it up would help. Not sure why chrysler is having so many of these issues lately.
 

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Or...whoever owned it before you was screwing with it.
It has nothing to do with that. My 07 4.7 liter is currently having the same problem with an exhaust leak right off of the drivers side manifold. I found a broken bolt a few weeks ago when I was checked it out. I'm currently at 117,000 and about 2 1/2 years ago I had that manifold off for the same issue. Replaced the gasket and all the manifold bolts then. And since more bolts are broken and the leak is back. Its a common issue.
 

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Discussion Starter #7
So this sounds pretty common. Almost like rear upper shock
bolts on an XJ. So did Chrysler come up with a TSB, and
address the issue? Different bolts, or torque specs? Still waiting
for the dealer to call me saying it's done.
 

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Discussion Starter #8
Got it back from the dealer today purring like
a kitten. The service advisor says that manifold
bolts have been breaking since the 50's. This is
the first time I've ever heard of it.
 

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I am sure they have been breaking as long as there have been exhaust manifolds but I personally think I am seeing more of them than in the past. I had a YJ with 150k+ miles and it never had any broken bolts, my XJ had 110k miles and none were broken, my friend had two CJ's and neither had any broken bolts, another buddy had a TJ with over 100k and it didn't have any broken bolts, my ram truck doesn't have any broken bolts.

My jk had two broken bolts at 30-40k. I know several people with Hemi's or 4.7's that have had broken manifold bolts multiple times. I kind of wonder if they are using a lower quality part, chinese steel has a bad rap.

Either way, an exhaust leak is pretty minor, a pain yes but minor.
 

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I had the same thing with my 4.7L. I think it may have to do with a lack of flexibility in the exhaust system design - as everything heats up it stresses the bolts at the manifold. My old 4.0L Cherokee had a manifold leak, and I learned that the newer Cherokee manifolds had expansion joints added to them.
 

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Anyone having this problem with the HEMI? I swear my hemi sounds like a lawn sprinkler and the dealership tech says "thats just the sound of an engine running" hahaha. I have been fixing engines long enough to know this is not a normal sound...:bang:
 

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This is a common problem with the commanders. It's an easy fix. Replace the manifold bolts with grade 8 and you won't have the problem with them breaking.
 

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Anyone having this problem with the HEMI? I swear my hemi sounds like a lawn sprinkler and the dealership tech says "thats just the sound of an engine running" hahaha. I have been fixing engines long enough to know this is not a normal sound...:bang:
I know there are lots of threads on these funny noises. My 2010 Hemi has sounded like it has an exhaust leak since new. Seems to be on driver side, worse when cold, hear it best with windows down. Only hear it under part throttle, not at idle.
Should I bring it in to dealer while still under warranty or will they just poo-poo it and say its normal?
 

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Discussion Starter #14
I know there are lots of threads on these funny noises. My 2010 Hemi has sounded like it has an exhaust leak since new. Seems to be on driver side, worse when cold, hear it best with windows down. Only hear it under part throttle, not at idle.
Should I bring it in to dealer while still under warranty or will they just poo-poo it and say its normal?

I test drove a Hemi before I bought mine,
and didn't hear anything like an exhaust leak.
You should hear it at an idle. Open the hood,
and stick your head in there. You'll hear the
T-T-T-T-T-T-T-T-T-T-T-T-T-T-T-T
 
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