aFe Twisted Steel Header — Jeep Wrangler / Cherokee / Comanche, Dodge Dakota 2.5L

Twisted Steel 409 stainless header for documented gas L4 2.5L applications

The aFe 48-46206 Twisted Steel header uses 1.5-inch 14-gauge mandrel-bent stainless tubing, a formed 4-to-1 collector and a 0.5-inch one-piece head flange. The exact selected guide identifies 409 stainless; current primary copy specifies MIG welding and retention of the stock catalytic converters. Current manufacturer applications separately name Cherokee XJ, Comanche, Wrangler YJ/TJ and Dodge Dakota gas L4 2.5L. The old 1983-start title is not current application evidence.

Key Features

• Selected aFe part 48-46206.
• 1.5-inch 14-gauge mandrel-bent 409 stainless primary tubes, as identified by the selected header guide.
• Formed 4-to-1 collector with optimized tube lengths and 100% MIG-welded construction.
• 0.5-inch thick one-piece head flange; connects to factory locations and retains the stock catalytic converters.
• Current primary describes direct bolt-on installation without cutting or drilling. The selected Wrangler guide still requires substantial intake, accessory and fuel-line work.
• Current exact manufacturer explicitly includes Dodge Dakota 1996–2002 gas L4 2.5L; this is not inferred from a related engine.
• NOT currently CARB exempt; manufacturer excludes California purchase and use on vehicles registered with the California DMV. Retaining factory catalysts does not remove this restriction.

Fitment

Current exact manufacturer applications: Dodge Dakota 1996–2002, Jeep Cherokee XJ 1991–2000, Comanche 1991–1992, Wrangler YJ 1991–1995 and Wrangler TJ 1997–2002, all gas L4 2.5L only. The selected complete exact-MPN named table supports the rows below, including four Dakota names and Wrangler Sahara 1991. No 1983–1990 application or other engine is inferred from the former title. The selected installation guide is headed Wrangler 1991–2002 L4 2.5L; it does not supply model-specific Dakota, Cherokee or Comanche procedures. Confirm the exact vehicle, installed configuration and emissions eligibility before purchase or installation.

Specifications

What's Included

• The 48-46206 kit includes one selected 409 stainless 4-to-1 header.
• Two 3/8-inch × 1.5-inch bolts, two 3/8-inch nuts and one intake/exhaust manifold gasket, as listed in the selected guide.
• Reuse original cylinder-head bolts and washers as directed. No separately numbered fastener or gasket replacement identity is established.
• No exhaust tips, cat-back piping, catalytic converters, intake filter, intake coupling, clamps or thermal wrap are established as supplied by the selected parts list.

About aFe Power

aFe Power develops application-specific intake, filtration, exhaust, cooling, tuning, suspension, drivetrain, and truck-performance components supported by product testing and documented installation requirements.

Related Parts

• Exact selected header and current applications/emissions restriction
• Selected complete 24-step Wrangler installation guide and parts list
• Complete exact-MPN named application table
• Shop headers and manifolds
• Shop aFe Power

FAQ

It is a MIG-welded 409 stainless 4-to-1 exhaust header for documented Jeep and Dodge gas L4 2.5L applications, retaining the stock catalytic converters.

No. Current exact manufacturer rows begin at 1991 for the listed Jeep models and 1996 for Dakota. Wrangler coverage is YJ 1991–1995 and TJ 1997–2002, not one continuous 1983–2002 YJ range.

The exact selected installation guide explicitly identifies 409 SS. Its 1.5-inch 14-gauge tubing, 4-to-1 collector, MIG welding and 0.5-inch head flange should not be replaced with generic retailer specifications.

No. The manufacturer says this product is not currently CARB exempt and is unavailable for purchase in California or use on vehicles registered with the California DMV. Retaining stock catalysts does not override that restriction.

The selected list contains two 3/8-inch × 1.5-inch bolts, two 3/8-inch nuts and one gasket. Original cylinder-head bolts and washers are reused. No tips, catalysts, thermal wrap or intake components are established as included.

No. The selected Wrangler guide includes battery, intake, throttle cable, labeled vacuum/electrical, fuel-injector harness, fuel-line and power-steering pump/bracket work. Professional installation and exact vehicle service procedures are recommended.

It gives no numerical manifold torque and no header-specific calibration settings. A generic footer refers to an aFe downpipe and aftermarket tuner; confirm its applicability with aFe rather than treating it as permission to disable or clear emissions faults.

No. Those are manufacturer claims; the exact selected chart, test vehicle, RPM and conditions were not located. Dakota, Cherokee or Comanche results are not inferred from the Wrangler guide or a different header.

Installation Instructions

1. Confirm aFe 48-46206 against the exact vehicle and installed equipment. Inventory the actual components and follow the selected manufacturer instructions and current vehicle service requirements.
2. Confirm the exact gas L4 2.5L application and manufacturer emissions restrictions. Read the full selected 24-step Wrangler guide. Obtain exact vehicle-specific service information for fuel pressure, fuel-line connections, fastener torque and accessory work before starting. Other approved models require their own exact procedures.
3. Allow the vehicle to cool, use protective equipment and support it at the specified vehicle jack-stand points. Disconnect the battery before exhaust work as the selected guide requires.
4. Remove the air inlet tube from the throttle body and set it aside. Remove the throttle cable from the intake assembly. Label and disconnect intake/throttle-body electrical connectors and vacuum lines so they can be restored correctly.
5. Remove the fuel-injector harness from the cylinder head. Disconnect the vacuum harness and brake-booster vacuum connection beneath the intake. Remove the fuel line from the fuel rail only using the exact vehicle’s fuel-system service and pressure-relief procedure; the selected guide does not supply that detail.
6. Loosen the belt tensioner and detach the power-steering pump and bracket from the intake; the pulley can be rotated to reach the bolts. No power-steering hydraulic-line disconnection is instructed. Remove the two exhaust-pipe attachment nuts and bolts.
7. Remove the intake/exhaust mounting bolts and intake manifold, then the remaining exhaust-manifold bolts and manifold. Inspect and clean the cylinder-head mounting surfaces, keeping debris out of all engine ports.
8. Place the supplied intake/exhaust gasket on the head dowels. Install the new header with the original bolts and washers finger-tight. Place the intake on the head dowels, install the remaining original fasteners and tighten the intake/exhaust mounting fasteners to applicable exact vehicle requirements. No numerical torque is printed in the selected guide.
9. Connect the exhaust pipe with the two supplied bolts and nuts. Reinstall the power-steering pump and bracket, refit the belt and adjust tension to vehicle specification.
10. Restore all vacuum connections, fuel-injector harness and intake electrical connectors. Reinstall the fuel line using exact vehicle service requirements, then the throttle cable and air inlet tube at the throttle body/airbox.
11. Reconnect the battery and recheck all work, including correct connection restoration. The selected guide gives no numerical torque, fixed clearance or mileage recheck interval. Keep factory catalysts and emissions controls; obtain aFe clarification of the generic downpipe/tuner footer rather than inventing header tuning instructions.

California Proposition 65 warning: this product can expose you to chemicals known to the State of California to cause cancer and reproductive harm.