Tackling a muffler replacement on my '01 this weekend. This is the first time I've attempted this particular project (i'm just a middling backyard tinkerer; have done the radiator and similar, easy projects). Any opinion on replacing the entire exhaust pipe (other than cosmetic)? Would sure save me some money but at the same time, I'm down there, already dirty, and I assume attaching the new muffler to a "clean" pipe will lead to a firmer seal.

Also, any advice on detaching old/attaching new in relation to the CAT would be appreciated. The old one looks to be welded on but from my readings it does not appear to be necessary to weld.

 

I replaced mine a week ago. My muffler had something loose and rattling around inside, so my first thought was to just replace the muffler. I had to cut the clamps off at both ends of the muffler, but the tailpipe wouldn't come off, so I cut it at the muffler outlet.

After looking at the tailpipe and rusted off hanger, I decided to replace the tailpipe as well. The tailpipe was ~$60, so not a big expense to replace a 15 year old part.

Since I had chosen to go with an other than OEM type muffler, I needed a short section of 2-1/4" pipe to make up for its shorter length. It went together rather easily. Removing the old was more of a PITA.

After driving around a bit I noticed that the turn down end was hitting on the shackle. The pipe had a bit of bend in it rather than straight exit, and had I thought it would be an issue, I would have tried to bend it straight prior to installing. My solution was to simply cut the bent part off, including the turn down, and replaced it with an 18" section of 2-1/4". It now exits straight out the back and is just shy of being even with the bumper. The removal of the turndown has decreased interior exhaust droning considerably.

 

If the pipe is welded to the cat it has already been replaced at least once, factory setup uses a flange. If thats the case just cut the pipe forward of the weld & stick a new length of pipe on it.

 

perfect, guys. thanks much.

just out of curiosity, where'd you come across the pipe for $60? All my quotes are at about $100, but that's at all the Big Box stores (Advance, O'Relly, etc). I'd like a quality piece that can handle a little backroading during hunting season, but don't require top of the line.

 

Get the Dynomax kit from summit
http://www.summitracing.com/parts/WLK-17340/

After the $75 rebate it works out to about $75 for muffler & pipe.

 

ah! I saw this kit...somewhere, minus the rebate. thanks. may put the project off for a week and save some coin. much obliged.

 

Hi

I am fitting a new exhaust on Sunday, it has the muffler & tailpipe all in one and real cheap on E bay very good quality.

http://cgi.ebay.co.uk/CHRYSLER-JEEP-...item255caa14e5

Stuart

 

just ordered the Dynomax from Summit, easily saved me over $100 (probably $200-$300 if you consider what a shop would've taken me for). thanks again for the advice and the link.

now...what to spend the savings on?

 

FYI: if the cat is original, factory/official method of removing pipe from it is to heat it evenly until it is cherry red, and then remove it very carefully. The factory did not weld cats in.

 

I was given an estimate of $350-$400 to have a performance muffler and tailpipe installed. The parts cost me 1/2 of that, and that includes the Magnaflow (SS and welded) muffler.

[/QUOTE]now...what to spend the savings on?[/QUOTE]

LOL! Its a Jeep XJ, there will be plenty of things that require $$. If you haven't already done it, I highly recommend a headlight upgrade, or a set of auxiliary lights.

 

funny you mention the headlights. was working on them tonite. cheap factory screws kept wanting to strip on me. finally just sprayed them with wd-40, let them sit overnight and try again tomorrow.