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Discussion Starter · #1 ·
Hello,

I have a 2004 Grand Cherokee 4.0L straight 6. I just had the motor completely rebuilt, and replaced the exhaust manifold with a Doug Thorley Header. Bolt-on replacement that has the same collector dimensions as the stock manifold. Of course it didn't come with new donut gaskets and I am unable to find them anywhere. These gaskets seal the Front Pipe (downpipe) with the two catalytic converters to the header collectors. I have tried many gaskets and none of them fit properly. I went to the Chrysler/Jeep Dealer and they said the gasket is not available by itself. I am at a loss here. What are you all using for these gaskets? Surely I'm not the only one who needs to replace these.

From what I measured, the diameter of the front pipe is exactly two inches. The gasket needs to be just under this to fit inside the cupped edge of the pipe. Then it crushes against the header collector flange to make a tight seal. Here are two pictures of the gaskets I need.
228271
228272


Here's what I've tried or researched and failed to do the job or they are not the right size.

FEL-PRO Exhaust Flange Gasket 60836. Diameter is too big. We tried to cut it and shorten it but it was just too loosey goosy and wouldn't seal or install right
Mahle

Walker Exhaust 31391. Same as above. Diameter is too big

MAHLE F7549. I have not tried this gasket but the dimensions say 2.75" diameter which is way too big.

Any help would be greatly appreciated.

Thanks
Nick
 

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Any shop that does mainly exhaust work will have them
 
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I'm with Ralph, I didn't think there were gaskets there. You simply push the pipes together and tighten the bolts, clamping the bell in the socket.
 

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Discussion Starter · #5 ·
I'm with Ralph, I didn't think there were gaskets there. You simply push the pipes together and tighten the bolts, clamping the bell in the socket.
So you're saying i'm making this harder than it needs to be? Thanks for the clarification. I will try running them with no gaskets and see if that works. Thank you!
 

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Any shop that does mainly exhaust work will have them
I have one in my ZJ. If it is not tightened down correctly and not tight enough it will leak. I believe I bought mine through Summit or Rockauto. Are they necessary? probably not, but it helps to make the correct seal. Made of an aluminum foil like material, they mold to the pipes after first use or two...
 

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I have one in my ZJ. If it is not tightened down correctly and not tight enough it will leak. I believe I bought mine through Summit or Rockauto. Are they necessary? probably not, but it helps to make the correct seal. Made of an aluminum foil like material, they mold to the pipes after first use or two...
Your exhaust is set up differently on the ZJ. The Walker exhaust parts diagram shows one for a '98 ZJ with a 4.0.
I just picked a random year to see.
For an '04 with a 4.0 they do not.
 

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I was just trying to give the OP a different opinion. I'm glad someone with a parts manual chimed in..

A WJ is different from both the XJ and ZJ, the engineers made sure that the WJ shared very few identical parts with the ZJ. They seemed to do it just because they wanted to. Most of the "re-engineered" parts are a slight change in the basic design of the parts, so the re-tooling was minimal.
 

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Hello,

I have a 2004 Grand Cherokee 4.0L straight 6. I just had the motor completely rebuilt, and replaced the exhaust manifold with a Doug Thorley Header. Bolt-on replacement that has the same collector dimensions as the stock manifold. Of course it didn't come with new donut gaskets and I am unable to find them anywhere. These gaskets seal the Front Pipe (downpipe) with the two catalytic converters to the header collectors. I have tried many gaskets and none of them fit properly. I went to the Chrysler/Jeep Dealer and they said the gasket is not available by itself. I am at a loss here. What are you all using for these gaskets? Surely I'm not the only one who needs to replace these.

From what I measured, the diameter of the front pipe is exactly two inches. The gasket needs to be just under this to fit inside the cupped edge of the pipe. Then it crushes against the header collector flange to make a tight seal. Here are two pictures of the gaskets I need.
View attachment 228271 View attachment 228272

Here's what I've tried or researched and failed to do the job or they are not the right size.

FEL-PRO Exhaust Flange Gasket 60836. Diameter is too big. We tried to cut it and shorten it but it was just too loosey goosy and wouldn't seal or install right
Mahle

Walker Exhaust 31391. Same as above. Diameter is too big

MAHLE F7549. I have not tried this gasket but the dimensions say 2.75" diameter which is way too big.

Any help would be greatly appreciated.

Thanks
Nick
Hello whitey482 any luck with finding those gaskets/Flange I am going through the same exact issue. Your help will be appreciated thank you again
 
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