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Old 01-13-2013, 04:35 PM   #1
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Exhaust System Replacement

Crawling around under my recent addition, I noticed that my exhaust system has quite a bit of rust. No holes, but I'd like to be proactive and replace it. Seems like most of the bolts are so rusted they'll have to be sawed off. Has anyone replaced their exhaust system? How much of a headache is it? Any tips, other than work rear to front?

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Old 01-19-2013, 12:34 PM   #2
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What's the best way to remove bolts this badly gone? Hacksaw?

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Old 01-19-2013, 12:36 PM   #3
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Angle grinder with metal cutting disc??
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Old 01-19-2013, 01:26 PM   #4
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yeah i agree with Shark 13.
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Old 01-19-2013, 09:33 PM   #5
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Yeah, the previous owner left me with some work to do
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Old 04-19-2013, 04:08 PM   #6
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Weather is getting to that point where I can begin the overhaul. Slid under there today and took some images. Fairly sure in the current condition, especially where the muffler meets the catalytic converter, that it won't pass an emissions test. Seems like a lot of work. Got an angle grinder in the other day, need to pick up a metal disk. Thinking the entire exhaust needs to be replaced. Anyone have a rough estimate of what the parts will cost me?

BTW, what's the name of the pan/tray the previous owner attached to protect the exhaust when offroading? Name is eluding me at the moment. Last image. Thanks









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Old 04-19-2013, 04:31 PM   #7
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Are you trying to think of skid plate?
Also, is there a reason why you wouldn't just leave it until it needs to be replaced? I could see buying a new one to be prepared or unless you were planning a road trip..
just curious...
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Old 04-19-2013, 07:01 PM   #8
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the plate itself is fine, but I'd have to grind off the bolts to replace the exhaust. Exhaust is looking rather rough, the connection of the converter to the muffler is a bit loose, afraid it would fail emissions and I want to transfer the registration from PA to NC, NC requires a current inspection to register a vehicle
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Old 04-19-2013, 08:12 PM   #9
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I'm about to do mine from the manifold back. All the parts are in the garage, I'm just waiting until after Jeep Beach to do it. I have cracks in the manifold and everything else is rusted to hell.

It looks like, besides the manifold, it's a pretty straightforward job. We'll see.
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Old 04-20-2013, 12:59 AM   #10
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You muffler has broken free in this pic (pretty common) and it probably rattles as slips back and forth on the pipe. I'd cut it just to the left of the clamp with a sawsall.

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Old 04-22-2013, 07:09 PM   #11
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Quote:
Originally Posted by bostiguy View Post
Are you trying to think of skid plate?
Also, is there a reason why you wouldn't just leave it until it needs to be replaced? I could see buying a new one to be prepared or unless you were planning a road trip..
just curious...
Not planning on replacing the skid plate. Have to cut the bolts off to get to the converter though. How rusted it looks, I imagine it doesn't have long left
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Old 07-26-2013, 11:21 AM   #12
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Well, finally getting into this project. Work has been hectic, non-stop, with maybe a couple free hours of cool weather every 4 or 5 days. Finally got some time off the past few days. Dropped the skid plate, and finally got the exhaust off. Took about 3-4 hours, two metal heads for the angle grinder, some prying, hammering, and even a snip with a bolt cutter...but got it free. O2 sensors aren't going to come off for love or money, so need to get some of those. And while it's off, I intend to remove a bunch of rust from the frame with a wire brush drill head, then hit it with some rust inhibitor and chassis paint. Already dropped the steps and started busting the rust. Looking a hell of a lot better.
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Old 08-01-2013, 06:38 PM   #13
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Alright, of course nothing is simple...

Got the front pipe and cat on, and hung the tail pipe. However, muffler seems to be almost too short, which I don't understand, as I laid everything by the old exhaust and it seemed to be the same size. How much overlap do the pipes require? And how do I get the clamps to hold the pipes together? I imagine I need to crimp them somehow? Do I need a pipe extension or something? Gave up on the muffler for today, any and all help appreciated
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Old 08-01-2013, 06:56 PM   #14
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The muffler is short because there is an extension on the outlet, same one I ripped out of mine, Just put a socket on the bolts behind the cat and just snap them off. Should break easy. Trash everything from the muffler back and get a new tailpipe and the correct muffler. I used an OEM type in stainless.
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Old 08-01-2013, 07:07 PM   #15
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it actually does appear there was an extension in there at one time. Can I find these at Autozone? How much torque do I need to crimp the pipes when applying the u-bolts?

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Old 08-01-2013, 07:08 PM   #16
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The muffler is short because there is an extension on the outlet, same one I ripped out of mine, Just put a socket on the bolts behind the cat and just snap them off. Should break easy. Trash everything from the muffler back and get a new tailpipe and the correct muffler. I used an OEM type in stainless.
above images are the old muffler, the new one appears to be short as well
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Old 08-01-2013, 07:37 PM   #17
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Quote:
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above images are the old muffler, the new one appears to be short as well
Yes you should be able to get one.

No reason to over tighten them initially, start with a good snug.
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Old 08-01-2013, 08:53 PM   #18
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smaller muffler won't cause a failure of emissions or create issues, reduce mileage, etc, will it?
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Old 08-01-2013, 08:59 PM   #19
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would this one be the right size? Not so sure I want to jury rig when I can do it right

Walker 18574 Direct Fit Muffler | eBay
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Old 08-02-2013, 04:12 PM   #20
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Quote:
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would this one be the right size? Not so sure I want to jury rig when I can do it right

Walker 18574 Direct Fit Muffler | eBay
Same type but stainless and worth it, Buy Walker Quiet-Flow SS Stainless Steel Direct-Fit Muffler 21337 at Advance Auto Parts
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Old 08-03-2013, 11:46 PM   #21
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Thanks...looking at that one, they have a pretty good online coupon at the moment

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