I have a 2002 Disco SE. 187,000 km. For the last few years, I've had a crack in the passenger side exhaust manifold. I've put up with the noise because after about a minute or so after starting, it gets quiet. (Obviously because the metal expands and no leak.) My question is, should I just put up with it or should I try to repair or replace it? I thought that perhaps a "header wrap" would make it quiet but I was worried about uneven temperatures in the manifold could make it worse. I've heard that filler such as JB Weld might do the trick. Replacing the manifold altogether would work of course...but that's pricey....and my luck, I'd snap or round out a bolt....

Suggestions, comments?

 

It’s a very simple repair to swap one out. You could get a used one from a reputable parts shop:

roverguy.com
roverlandsparts
paul grant
and a few others.

get new bolts, studs, gaskets and spacers and you can swap it in an hour or two

or pony up for a brand new one. They’re $400 I think though. I’ve used used ones several times with success and no recurrent issues

 

Just change it, l've done a couple cracked manifolds and bolts come right out. Just hit them with WD40 a few days in advance, buy a new gasket set, manifold to head and y-pipe to manifold. Should be able to find a good used manifold easily, even in Canada. PM Richard Fox, he put headers on his last build and also had a couple scrap Dll's, he's in southeastern Ontario...so he might have one.