Trouble installing

[DaemonForce]

Does anyone here ever have trouble installing their exhaust header? I can't get the bolt holes on my manifold to line up with the ones on the engine without using some bar to bend the pipe. After that's done I have issues threading the rest of the bolts into place. What am I doing wrong? :/

[eaglefreek]

Unfortunately, it's quite common with many engines from the heat cycling. Sometimes they get so bad you have to toss them and get another one.

[DaemonForce]

No. This is not acceptable. This header is a replacement for the cracked garbage I've been using up until now and these bolt holes are within 1/4" of lining up with the holes on the head. I don't have a ton of cash to spare for yet another header and I need this working today.

[eagleman]

I had the same problem when I reinstalled my stock one. Didn't take long to figure out why both the front and rear ones were busted off to begin with. What I did was put the rear one on the rear stud and start the nut. Then I installed the two middle ones with the rear middle one first and then the front middle one. My front stud was then off around a eighth to three sixteenths. I then used a pry bar and pryed the exhaust manifold down and after many not so nice words and attempts I finally found a way to not only pry it down but also slightly forward allowing me to finally install the front stud. I then started the nut and then went back and installed the rest of the bolts. Then I torqued them to spec and in the correct order. Don't know if all of the exhaust manifolds are warped like mine was but anyway thats how after many failed attempts I finally got mine on and tightened up. Hope this helps with your problem and question. I also used new grade eight bolts and washers I purchased from our local jeep dealer. Anyway good luck and be careful!

[DaemonForce]

This installation theory would have helped me a little earlier. I gave up and gave it to a machinist. His problem now. :/

Oh and something very interesting that probably threw everything off in the first place. When I unbolted the manifold, there was no rear bolt. So I'm actually missing a manifold bolt.