Find out how it cracked. Probably didn't fit proper because it was contacting the exhaust manifolds runner right there, cracked when tightened down

 

We're pretty sure that's what happened. I've already got another intake on the way and can hopefully try to install next weekend. Which is better to grind to fit: the intake or the header? Also, do you think i can reuse the gasket & manifold bolts or should I get replacements?

 

you should be able to reuse them.

I'd do a very light grinding on manifold until it's close to fit, and worst case use a ball pin hammer to tap the exhaust manifold a bit to make it fit.

that's what I had to do to put the borla on mine with that manifold

 

Thanks! I've got Sunday tentatively scheduled for the re-install, depending on when the new intake shows up. On Friday, I think I might drive up to one of the Marine bases nearby to use their auto hobby shops to install new front brakes, adjustable track arm, motor mounts, & tranny mount...but I'm leery about driving it. As long as I'm moving at highway speeds, the engine stays cool. But idling in traffic or going slow gets kinda scary. I hate to think I'd waste a day off not installing stuff, but maybe I should so's not to overheat the engine.

 

It's been a rough month or two since I last reported in (family medical emergencies and what-not), but I finally got a new intake manifold installed. Here's pictures of the old one:







So yeah, incredibly obvious where the vacuum leak was AFTER it was uninstalled! With the new one installed, the Jeep idles at about 1200 rpm after warm-up. I'm hoping it's an ECU reset/tune up thing. We smoked it after install with no leaks seen. Here's hoping!