Changing intake manifold gasket on my 2005, what can I do to make the job less of a nightmare?

TheManWithNoName · Jan 1, 2026

Hey guys, I'm about to replace the intake manifold on my 2005 I6 and I'm wondering if there's anything I can do to make sure the job doesn't become a nightmare. The Jeep has very little rust anyway, but I'm already planning to soak the exhaust/intake manifold with rust penetrant. Should I remove the fender to have better access to the lower bolts?

Thanks,

macleanflood · Jan 1, 2026

For starters start hosing down all the exhaust bolts with your favorite penetrating lubricant.

-Mac

TRevs · Jan 1, 2026

I did the manifold on my ‘95 YJ and did not remove the fender. Rather I used a variety of socket extensions, 1/4” and 3/8” drive, wobbly and not. You can stack them up and get access from far away through tight spaces.

PG. · Jan 1, 2026

Definitely do not need to remove the fender. I have done it a few times. Just move things out of the way and be careful with the injector connectors sometimes they can be fragile since they are plastic.

Moglocker · Jan 1, 2026

PG. said:
Definitely do not need to remove the fender. I have done it a few times. Just move things out of the way and be careful with the injector connectors sometimes they can be fragile since they are plastic.

I just took the exhaust (mini cats) off and at the the other end at the third cat, with that assembly out of the way it was easy to do from underneath.

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Changing intake manifold gasket on my 2005, what can I do to make the job less of a nightmare?

TheManWithNoName

Member

macleanflood

I break sh!t

TRevs

TJ Enthusiast

PG.

Jeepn for dummies

Moglocker

TJ Expert

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