Jeep Strokers

7120 with a late model horse shoe intake manifold.

#4 exhaust tube fitting the bottom of the intake manifold.

Hate to think I just spent over 500 bucks on a new header and have to modify it to fit.

Before I decide what to do has anyone else had this issue ?

Thorley wants me to send it back on my dime and they will check it of their fixture. If I clearance the offending tube then there goes the warranty.

Called and talked to Russ......Thanks for taking the time my friend............

He confirmed my suspicion that the later model intake with the larger plenum is the culprit.

Doubt very much there is anything wrong with the header. It was designed to clear the log style intake. Going to go out on a limb here and say that other companies designs might end up having the same issue.

Plan of attack on the Thorley, cut and reweld a section or heat it up and smush it in a hair.........

Hmmmm.......

jsawduste wrote:He confirmed my suspicion that the later model intake with the larger plenum is the culprit.
Doubt very much there is anything wrong with the header. It was designed to clear the log style intake. Going to go out on a limb here and say that other companies designs might end up having the same issue.

I think you're onto something there.
That said, I didn't have any clearance issues between the Borla header I had installed back in 1997, and the '01 intake manifold I had installed in 2009.

I have a Doug Thorley header using a newer style horseshoe intake and it clears just fine. I'll check the# but I think it's the same.

Mine is a HDX 635, sorry.

Turns out the 634 (thanks Skyline) ALMOST fits with the late model intake.

The plenum clearance is fine, however there is a small hump underneath where the intake runner joins into the plenum. The other 5 primary tubes on the header radius down before this "hump" but not #4 though.

A little grinding on the intake combined with a few well place hits with a big ass hammer (calibrated for balance and weight distribution) fixed the offending primary tube.

The hammer process was a bit painful but brutally effective.

Called Thorley and the CS guy was pretty cool. He said they would update the product description and the instructions so future customers would know.

Thanks to all !!