TrueBlueXJ

While wrenching on the Jeep a few weeks ago (which I do almost every weekend), I found something that... well, kinda sucks. The last bolt through my manifold, nearest to the firewall, is broken off. I assume if I pull the manifold off, I'll find it broken off flush with the head (of the motor, not the bolt ). So what the hell should I do? Remove the manifold and everything near it (throttle body, intake, master cylinder....) and try to drill / easy-out a Grade 8 bolt out of my head. Or... should I removed the head and try to attack it from there, but have to replace head gaskets? Orrr... should I just not care, because it's too much work to remove and replace ONE bolt.

TIA.

5spd-XJ

What were you trying to do?

TrueBlueXJ

Nothing. I just had the hood up and heard a bit of leak, went to check the manifold for a crack and found a bolt missing. I stuck a long nail through the bolt hole to see if maybe it walked out, but I hit steel, so I'd say the bolt sheered off at some point. I had a broken motor mount for about a week, so that might have had something to do with it. Either way, the bolt's gone bye bye, and the manifold's gapped in the back, causing it to leak.

5spd-XJ

well, im not sure what the 2.5l engine has in the way, or how tight it is back there, but it more than likely will not be an easy fix, but it will make the job easier to remove anything you can that is in the way, taking shortcuts helps for some things, but i find that its best to just spend a few extra mins removing something, than spending the whole time trying to fight with it in your way.

hope that helps

TrueBlueXJ

Yeah, that's what I was thinking. I planned on removing the intake and throttle body, and possibly master cylinder if need-be. The 2.5L isn't set up much different from the 4.0L, it's just shorter. Makes changing the serp belt easier.

5spd-XJ

Well, best of luck when you tackle that project.

finneys98xj

True I wouldn't worry about it til something goes wrong that force you to pull the head. The intake and exaust on the 4.0l has to come off before you can pull anything to get near the bolt. It is so tight to get to the botttom bolts its not worth it. Unless if bothers you that much and you want to run the risk of mess the head up, DON"T.

EDIT:
Wait if it is like my 4.0L Head the last and first bolts are exactly studs coming out the heads!

okcjeeper

I can tell ya if it was me I'd pull the head and take it to a machine shop and have them remove the it and retap if needed..That's just me cause you do not want to screw up the head cause it will cost a bit to replace without a core...

BlueXJ

I would make sure the rest are snugged up good and tight then see if you still have the leak. If you do then you are going to have to dig in and drill it out. If not you can probably get away for now since you have replaced the motor mounts.
As for drilling it out it would be much easier to drill it straight on a drill press. I know that is a lot more work but it will let you do it right instead of breaking drill bits in the attempt to drill it with a hand drill.

finneys98xj

Does anyone know if it is a stud or a bolt?

okcjeeper

Should only have 2 studs..1 very bottom front and 1 very bottom rear.

finneys98xj

I know 4.0l do but I was asking about 2.5L.

TrueBlueXJ

I'll have to look, but I'm pretty sure it's a bolt. It's the top mounting hole, next to the the firewall. I'll check it after work today.

finneys98xj

If It is made like the 4.0l the farest back exust is a stud. For your sake hope it is a bolt.

BlueXJ

When you check it let us know. My older FSM shows it as a bolt on your 4 banger, but my FSM is for an 89 not a 96.