Cracked exhaust manifold on my 95,is this common?

[350TPI]

This is my first post.I just picked up a 95 corolla from the TV station i work for.They were retiring it and let me have it cheap ($200!).Since day one i noticed the exhaust sounding really raspy.I noticed the exhuast manifold has a crack in it.I went to the junkyard and the 7afe they had also had a crack in the exact same spot.Has anyone repalced theirs?How hard was it?So far i am loving this car.It gets between 33.4-38 MPG in the past 3 weeks.Thanks for any replies.

[Pineapple]

Yeap they all crack. Its easy to change as long as you can get the nuts out. You'll need power tools, big arm or breaker bar. Get a header. You'll get more power. They don't crack that easy. Even if they crack, a muffler shop can weld them up. Also it cost about the same as the manifold.

[350TPI]

So you are saying i can just get the crack welded up?Does the heat shield com off easily?Thanks for the reply,chris.

[Pineapple]

Yes and no. Header is easy to weld, stock casted manifold is not.
Replace the cracked manifold with new one or header.

[tashirosgt]

The manifold bolts get rusted since they are splashed with water while they are hot. Before you do the job, locate the nuts and bolts must come out and put some penetrating oil on them while the engine is cold. Then drive the car a few times. If you break off a bolt that goes in the engine block you won't have enough room to use the usual remedy of drilling a hole and using an "easy-out". You will end up having to remove the radiator or perhaps the engine to do this work.

Don't know about the 7AFE, but on the 4afe, the bottom of the manifold connects to the exhaust pipe with two studs and nuts. My advice is to get new studs and leave the old studs in the old manifold. Use a nut splitter on the nuts if you have to.

The little bolts that hold the heat shield usally snap off. I prefer to reuse the old heat shields if they are the OEM shields instead of the sheilds that come. The best thing would be to get a new aftermarket manifold if they are available. Most new ones come with the gasket and bolts for the heat sheild. You will have to get the studs at an auto parts store.

I think one reason replacement manifolds crack is that their replacers don't use a torque wrench and they get the bolts tightened wrong. Don't get the bolts overtighted or get one much more tight than another. After the car has been drive a few times with a new manifold, go back and recheck the torques.

[CorollaDX-R]

it is pretty common to crack that stupid header cuz heat couldn't go anywhere... a good way to solve that problem is to take off the stock heat shield cover for the header to let more air go around the header to cool it... i crack my header once after i replaced it i did not put the cover on and the header had no problem since that...

[Param]

[quote=tashirosgt;947718]The best thing would be to get a new aftermarket manifold if they are available. Most new ones come with the gasket and bolts for the heat sheild. You will have to get the studs at an auto parts store.

I have a 99 XLS. Last week I got the rear one (Left) welded, & it is still holding. However, after timing belt change the next day, I heard a fine whining noise from the front. Front manifold cracked & was leaking through the heat shield. Got that welded, but did not last more than 5 minutes..

I have yet to see an aftermarket one with heat shield. I would prefer to get one with heat shield. My fear is not having the heat shield could damage wires, sensors, or plugs with the heat. Do you know of any aftermarket one with heat shield?

I do need to replace the flex pipe soon. Last time got the flex pipe welded only 2 1/2 yrs ago. I was hoping to get stainless steel up to the Catalytic. However, so far what I have seen are polished headers without heat shield. Not having the heat shield, especially the rear (Right) one really concerns me.

Going for the Dealer for manifolds alone cost $160 (L) +180(R). Never mind the pipe.

I am not after performance setup. Rather, looking for a quiet and long lasting (relatively) setup. Any advice on new exhaust system for 99 Avalon?