I recently pulled the downpipe to install a new clutch kit on my 96 XJ. I ended up cutting the bolts holding to to the exhaust manifold because they were extremely rusted. Im now in the process of reassembling the exhaust and cant seem to get the old bolts out. Any suggestions are welcome, tired of the bruised knuckles and spend Dremel cutting wheels. Additionally, both bolts for the slave cylinder sheared off with minimal force applied. Ive been soaking them with PB for a few days to no avail. Im guessing my next step is to drill them out? I worry about damaging the threads. Any suggestions on this issue are also welcome. Thanks!

 

i believe those are a press fit bolt. they have splines so they don't turn, not threads. but i could be wrong.

 

So I think the part number for those studs in the header/exhaust manifold is J4007109

https://www.moparpartsgiant.com/part...~j4007109.html


So it looks like caged is correct about the press fit.

I think the studs for the slave cylinder are 6032878.
And it looks like the specs for the stud are .312-18x2.00.

https://www.moparpartsgiant.com/part...d~6032878.html

Do you have a parts catalog for your '96?

https://www.cherokeeforum.com/f2/research-249236/

Should probably go look for yourself to make sure I am right. LOL.

 

For the exhaust cut the hex head off and punch them through.

For the slave mount I would probably get them red hot and turn out with vice grips. That or weld a nut on after I got them red.

 

X2 on the exhaust. Press or punch the old ones out and replace with regular hex-head bolts with a lock washer under the head. If you can find them, bronze are less likely to corrode but I've just used regular grade-8 bolts and had no problem getting them off 5 years later when I replaced the exhaust. Good luck on the clutch cylinder bolts. Steel is bad about seizing into aluminum, stainless is even worse for some reason. I'd start with some heat and penetrating oil, then use vise grips and work back-n-forth until they loosen up.

 

Awesome info. Thanks. I ordered the FSM a few days ago and still waiting for it to arrive. Had some trouble finding the 96 FSM for some reason and hope i bought the right one.. they had 87-95 and 97-01 on the site that i found recommended here on CF.

 

Will definitely try the heat and wiggle method, thanks for the advice. Didnt think to use bronze for the exhaust, great idea. Now to do.some sleuthing and see what I can find!

 

For a '96, the only true manual is a paper one, which are sometimes available on Ebay etc

In any case, the '95 is correct for almost everything except the engine electrics (which are OBD2, so 97 is correct for that)

The best bet is to free download both from cruiser54 website, along with the 94-96 Parts Manual