all muffler and exhaust questions go here!!!!!!
#4651
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Join Date: Sep 2012
Location: Oswego, IL
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Year: 2001
Model: Cherokee
Engine: 4.0L I6
what to do with exhaust?
2001 xj. there is a leak at the flange where converter and muffler meet.
the bolts rusted through the cat converter side as shown in the picture.
So what to do? everything is original I believe. 140k ish miles.
The flanges on both side are solid and solidly connected to the pipe.
My plan was to remove the bolts and replace the hardware.
I cut the bolts and tried to drill out the holes on muffler flange. even with a cobalt bit i cant drill the ****!! its too heat treated barely made a dent.
So now what?
I could do a vat back replacement but im worried about other bolts for hanger placement breaking off. they look horrible and rusted to hell.
honeslty it seems like getting into this at all would mean cutting everything out with a torch that i dont have and replacing the whole system from manifolds back. All the connections are junk, not workable.
what do you guys think?
the bolts rusted through the cat converter side as shown in the picture.
So what to do? everything is original I believe. 140k ish miles.
The flanges on both side are solid and solidly connected to the pipe.
My plan was to remove the bolts and replace the hardware.
I cut the bolts and tried to drill out the holes on muffler flange. even with a cobalt bit i cant drill the ****!! its too heat treated barely made a dent.
So now what?
I could do a vat back replacement but im worried about other bolts for hanger placement breaking off. they look horrible and rusted to hell.
honeslty it seems like getting into this at all would mean cutting everything out with a torch that i dont have and replacing the whole system from manifolds back. All the connections are junk, not workable.
what do you guys think?
Last edited by stimp774; 11-01-2016 at 05:52 PM.
#4652
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Year: 1998
Model: Cherokee
Engine: 4.0L I6
Hey guys, I need to replace my cat. I was trail riding and after 18 years of rust, its fell apart on the trail. Everything after the cat is fine, but I am taking the opportunity to replace the muffler as well due to rock damage. I believe the stock size exhaust tubing before the cat is 2.25". I am wondering if I should get a 2.5" cat and muffler so I can clamp the system down. Iv'e never had to replace this much of an exhaust system at once, and I think that I am overthinking things, but what are your opinions on this? Thanks in advance!
#4653
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Join Date: Oct 2011
Location: Sussex cty NJ
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Year: 1996
Model: Cherokee
Engine: 4.0
Hi, I have a 4cyl Cherokee that needed everything from the down pipe back. I bought everything and hooked it all up, and the new cat is too big for the factory downpipe. Is the downpipe from the 2.5 the same as a 4.0? The cat is obviously mounted in the same place on both but I have a feeling the downpipe is different. I have been unable to locate a downpipe specifically for the 2.5 and if the 4.0 is the same then I'll have my problem solved.
#4654
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Join Date: Sep 2010
Location: Lantana, Fl
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Year: 1996
Model: Cherokee (XJ)
Engine: 4.Slow
Hi, I have a 4cyl Cherokee that needed everything from the down pipe back. I bought everything and hooked it all up, and the new cat is too big for the factory downpipe. Is the downpipe from the 2.5 the same as a 4.0? The cat is obviously mounted in the same place on both but I have a feeling the downpipe is different. I have been unable to locate a downpipe specifically for the 2.5 and if the 4.0 is the same then I'll have my problem solved.
#4655
Anyone running Borla XR-1 mufflers with stock setup? Looking for a replacement muffler with an aggressive note at idle and woot but minimal drone on cruising speeds.
#4656
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Join Date: Sep 2015
Location: PA
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Year: 2000
Model: Cherokee
Engine: 4.0L
Hey guys, I need to replace my cat. I was trail riding and after 18 years of rust, its fell apart on the trail. Everything after the cat is fine, but I am taking the opportunity to replace the muffler as well due to rock damage. I believe the stock size exhaust tubing before the cat is 2.25". I am wondering if I should get a 2.5" cat and muffler so I can clamp the system down. Iv'e never had to replace this much of an exhaust system at once, and I think that I am overthinking things, but what are your opinions on this? Thanks in advance!
#4657
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Year: 2000
Model: Cherokee
Engine: 4.0L
O2 Sensors 2000 XJ
I was just wondering if anyone knew what the original O2 sensors would have been on a 2000 XJ with a 4.0? I have just put a Golen 4.6 stroker into my xj and have been told by the engine builder that the engine doesn't really like to work with aftermarket O2 sensors/non-factory sensors. Thank you in advance!
#4658
Moderator CF K9-unit
Join Date: Apr 2012
Location: Alaska
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Year: 2000 sport
Model: Cherokee (XJ)
Engine: New 4.0l from s&j engines
I was just wondering if anyone knew what the original O2 sensors would have been on a 2000 XJ with a 4.0? I have just put a Golen 4.6 stroker into my xj and have been told by the engine builder that the engine doesn't really like to work with aftermarket O2 sensors/non-factory sensors. Thank you in advance!
#4659
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Year: 2000
Model: Cherokee
Engine: 4.0L
#4660
No, I don't lick fish.
2001 xj. there is a leak at the flange where converter and muffler meet.
the bolts rusted through the cat converter side as shown in the picture.
So what to do? everything is original I believe. 140k ish miles.
The flanges on both side are solid and solidly connected to the pipe.
My plan was to remove the bolts and replace the hardware.
I cut the bolts and tried to drill out the holes on muffler flange. even with a cobalt bit i cant drill the ****!! its too heat treated barely made a dent.
So now what?
I could do a vat back replacement but im worried about other bolts for hanger placement breaking off. they look horrible and rusted to hell.
honeslty it seems like getting into this at all would mean cutting everything out with a torch that i dont have and replacing the whole system from manifolds back. All the connections are junk, not workable.
what do you guys think?
the bolts rusted through the cat converter side as shown in the picture.
So what to do? everything is original I believe. 140k ish miles.
The flanges on both side are solid and solidly connected to the pipe.
My plan was to remove the bolts and replace the hardware.
I cut the bolts and tried to drill out the holes on muffler flange. even with a cobalt bit i cant drill the ****!! its too heat treated barely made a dent.
So now what?
I could do a vat back replacement but im worried about other bolts for hanger placement breaking off. they look horrible and rusted to hell.
honeslty it seems like getting into this at all would mean cutting everything out with a torch that i dont have and replacing the whole system from manifolds back. All the connections are junk, not workable.
what do you guys think?
#4663
Is it quiet like stock? I have the replacement muffler and a smaller Cat Conv on from like Midas etc, all those places say that is all that is available, unless get factory parts at a grand....mine is not bad but sounds like the muffler has hole in it...lol...is all new, but Midas, and other shops says being smaller is why louder and is all they can get...
#4664
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Join Date: Jun 2014
Location: Eagle River, Alaska
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Year: 1999
Model: Cherokee (XJ)
Is it quiet like stock? I have the replacement muffler and a smaller Cat Conv on from like Midas etc, all those places say that is all that is available, unless get factory parts at a grand....mine is not bad but sounds like the muffler has hole in it...lol...is all new, but Midas, and other shops says being smaller is why louder and is all they can get...
#4665
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Join Date: Feb 2009
Location: Houston Tx.
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Year: 1995
Model: Cherokee
Engine: 4.0
Anyone have MagnaFlow or Thunderbolt high flow cats? Did your MPG improve over stock? Power? Engine run cooler? Will they last long? (Not talking rust, I live in the south)