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Old 04-23-2012, 08:03 AM   #1
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Muffler/ Exhuast system

Are there any systems out there that are a direct fit for the YJ? My muffler has rusted through and I need to replace at least the muffler, maybe if reasonable the whole exhaust system. Muffler for sure if someone knows of one I won't have to mess with to get it on?

I'm handy but cannot weld for sure!!

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Old 04-23-2012, 08:16 AM   #2
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Quote:
Originally Posted by Dlong
Are there any systems out there that are a direct fit for the YJ? My muffler has rusted through and I need to replace at least the muffler, maybe if reasonable the whole exhaust system. Muffler for sure if someone knows of one I won't have to mess with to get it on?

I'm handy but cannot weld for sure!!
Try after market like flowmaster or something like that

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Old 04-23-2012, 10:57 AM   #3
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DO you know of hand if it is a direct fit or what kind of mods I will need to make. Trying to figure this out before I go get knee deep in it. Thanks.
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Old 04-23-2012, 10:59 AM   #4
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Quote:
Originally Posted by Dlong
DO you know of hand if it is a direct fit or what kind of mods I will need to make. Trying to figure this out before I go get knee deep in it. Thanks.
I bought my flowmaster and took it to a mechanic they charged me less than a 100.00 to cut out the old and put then new in.. So not real sure
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Old 04-23-2012, 12:44 PM   #5
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Dynomax Exhaust System (catback) 17309 - $140 on Amazon
Dynomax Mail-in-rebate - $75
MagnaFlow Cat - 23229 - $82.50 on Amazon w/ $10 shipping

Came with all the parts, no welding necessary. Did it over the weekend...

Any questions pm me, I might do a quick write up and put up a video of the sound..

It got a couple peacocks turned on yesterday, no joke
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Old 04-23-2012, 12:56 PM   #6
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X2 for the Dynomax, cannot beat the price and its an easy install.
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Old 04-23-2012, 01:34 PM   #7
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Try online; Morris Jeep or 4wd.com. They boh offer "direct replacement" kits where you can get from the manifold back or from the cat back. I got the full manifold back kit from Morris Jeep for around $400 including all pipes, the muffler, the cat and all the hangers. No welding required. It is a simple bolt on but start spraying PB Blaster now on the connection to the manifold and the bolts for the skid plate so they will come off easier, spray everyday for a couple of days.

Only other hiccup was kit had a fitting for an O2 sensor in pipe that needed to be plugged. You can get the plug for it from autozone made by K&N for another 10$ or find it several places online. Fitting is M20x1.5 thread.

It is a lot cheaper than having a shop do it and it will all be new!
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Old 04-23-2012, 01:38 PM   #8
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How loud is the Dynomax kit? Looking to keep things stock sounding.
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Old 04-23-2012, 01:44 PM   #9
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I really like the sound of the Dynomax... It's hard for me to compare to my old stock sound because my cat was clogged and my muffler had a dent in it.

The sound I get from the Dyno and MagnaFlow cat is real nice. It's not loud, but you hear it (mostly at low rpms) and it's an enjoyable sound.
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Old 04-23-2012, 02:44 PM   #10
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And all of these fit the 6 cyl 4.2? Or are both 1990 (4 cyl / 6cyl) exhaust systems compatable? Thanks stretch!!
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Old 04-23-2012, 03:22 PM   #11
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Can't help with that info, I have the 4.0 in my '92
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Old 04-23-2012, 07:57 PM   #12
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6 and 4 are different if going for direct replacement from manifold back
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Old 04-24-2012, 10:35 PM   #13
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Dlong, here is the cat I have. There was a nub that stuck out. Maybe thats what you were talking about. If so, maybe someone could identify what it is on your jeep.

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Old 04-25-2012, 11:58 AM   #14
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It look slike it. I am going to drop the plate tonight or tomorrow so I can get a definate look at it. Still not sure what the valve is though. Got no response from the original post. Someone has got to know what this thing is??
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Old 04-25-2012, 03:09 PM   #15
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hard to tell in the pic, but it looks like a hanger. the type that fits into a rubber piece so your exhaust can move with the engine but not drop. all the toyotas I've had were full of em, as for it being hooked to a hose going to your breather, it doesnt sound right, all it would do is plug off the hose. I know the piece is hollow, but it doesnt actually go into the cat
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Old 04-26-2012, 07:54 PM   #16
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The one I just installed had same thing. It is capped off. I was of opinion it might be part of manufacuring process but really dont know.
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Old 05-06-2012, 05:29 PM   #17
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I have a '89 yj 4.2 lit. I'm just dealin' with a cad. conv. issue, the tube coming out of the side is acully for the pulse tube to connect to. It's a fed. requirement here in calif.There's the Pulse down tube that goes to the converter, that your wondering about. Then there's the upstream tube that goes to your exhaust pipe. something to do also with my oxegen sensor. there's also two hose's that continue to the air cleaner.In the Haynes repair manual, look at chapter 6-6.
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Old 05-06-2012, 05:43 PM   #18
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Quote:
Originally Posted by stretch05 View Post
Dynomax Exhaust System (catback) 17309 - $140 on Amazon
Dynomax Mail-in-rebate - $75
MagnaFlow Cat - 23229 - $82.50 on Amazon w/ $10 shipping

Came with all the parts, no welding necessary. Did it over the weekend...

Any questions pm me, I might do a quick write up and put up a video of the sound..

It got a couple peacocks turned on yesterday, no joke

I want this write up
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Old 05-09-2012, 02:13 PM   #19
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Well here it goes....

First, I went to a friends to use his tools...

I would suggest having an impact wrench and a recipricating saw.
also deep sockets

I read many people dropped the skid plate, but I didn't want to and it worked out alright... tough around the catalytic converter, but far from impossible

I started by disconnecting the cat. 4 bolts, 4 nuts. The two on the outside broke off when I used the impact wrench, so I didn't need to get a wrench behind and on to the nuts, which was sort of tough when installing the new cat while the skid plate was still on.

The two bolts on the inside required getting a wrench on the nuts, luckily there was a hole in the skid plate that allowed me to stick a wrench up and on to them. The nuts and bolts on mine were 14mm, since I broke a couple, I went to a parts store and got 4 new bolts and nuts, I think they ended up at 17mm or something, idk.

Then I took the clamps around the muffler off. Again, 14mm socket and needed the impact wrench.

My cat was welded to my muffler so I used the recipricating saw to cut them apart. My exhaust pipe was also welded to the muffler, so I sawed the pipe off on that side of the muffler. Now that I've finished the job, I realize I could have just cut the pipe on the exhaust side of the muffler.

The cat came out on the exhaust side of the skid plate.

The muffler was cut on both sides.

The exhaust pipe slid out with some twisting and turning (it goes up and over your rear trac bar). It is held up by a couple pins inserted into rubber mounts.


REINSTALL

Next I got the bolts started on the cat.

The muffler was not attached to either the cat or the exhaust pipe which was nice about the dyno.

I ran the exhaust up and over the trac, which was tough. My buddy just rotated from the rear of the jeep and I pulled, eventually it came though. If your have the rear trac removed, even easier job.

Once it was through, I put the pins through the rubber mounts. Ran the pipe into the muffler, clamped it tight.

Ran the cat pipe into the muffler, clamped it tight.

Tightened the bolts on the cat and started her up.

My cat must have been bogged, cause my jeep runs noticably better than before.

Not loud, louder than stock. I like it.
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Old 05-09-2012, 03:00 PM   #20
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Not sure if this matters to ya about choosing a muffler or not but I have a 30 Series Flowmaster on my 93 4.0... I'm also running a aftermarket headed and no cat. Mines got a really aggreasive sound out the back but it's nice and quiet on the inside. Kinda Sounds like a Chevrolet V8 with dual exhaust. I'm assuming the header and no Cat is why mines so deep.

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