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Old 04-07-2012, 06:47 PM   #1
Join Date: May 2009
Location: Underhill, Vermont
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replacing cat and muffler advice

Hi all - 93 yj base 4 cylinder. My local mechanic who I trust said that I need a new cat and muffler before my next inspection. I would like to do it myself.

Is this something that is done without removing the cross member? I have done u-joints, water pump, tailpipe, etc, but nothing "in the middle" of the yj. Does the cross member actually support the transmission? Is it a mini skid plate?

Just like to find out how its done. I have a chiltons for the yj but it doesn't mention the cross member at all in the process, so I assume it can be done around it?

Final question - since I am replacing the cat and the muffler, can I put this combination together on my bench and then insert it in series all at once? This would seem quicker but as the section is larger could be a pain to get in there?

Thanks for your input all, just trying to keep her moving down the road!
The Captain is a one eyed Dwarf, who's throwing dice along the wharf. In the land of the blind the one eyed man is King. - Tom Waits
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Old 04-07-2012, 09:33 PM   #2
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I just replaced my cat and muffler today... I got the universal fit cat ($112) from Autozone because it was $40 less than the OEM style. the OEM style muffler was $35. Yes, you can put the cat and muffler together outside the Jeep and you won't need to pull the cross member. the problem I had with the universal cat was it has 2 1/2 inch inside diameter inlet and outlet pipes and the pipe from the exhaust manifold is 2 1/4 outside diameter. Neither Autozone nor Advance had an adapter that would fit, so I had to go to a muffler shop and have them make a custom piece. The cat to muffler connection wasn't quite as bad and I was able to use an exhaust clamp and get a nice tight seal. It can be done in the driveway but I promised my wife I would take the next exhaust replacement to a muffler shop. The local shop quoted me $225, and I had $160 in parts (plus gas from the two extra trips for adapters), but I think my sanity is worth the other $65.

'94 YJ, 2.5L, manual, 235/75/15, 164,000+ miles
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Old 04-08-2012, 12:06 AM   #3
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when is your next inspection?

Why not save your pennies till then, and get a performance muffler like a Flowmaster and a hi flow cat, get a shop to weld it on and your done?

In cali, inspections are every 2 years, and we only do emissions inspections, so.....
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Old 04-08-2012, 09:05 AM   #4
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Thanks for the reply. If I choose to go with a little more $ and get the OEM replacement will the flanges/pipes line up without need for adapters, etc? While I want to do this myself, I would rather spend a little more money and just have it "work". I have 12 cord of logs in my driveway to buck/split/stack, roof to replaced, two weddings to go to, and a baby in the oven on the docket for this summer. Looking for the easiest solution that I can do myself.

Anyone know a good, stock-ish, price conscious brand that would be a good OEM replacemnet for the cat and muffler for a 93 4cylinder?

@2xs - in Vermont it is every year we get the inspections, and while I have until Sept this year, I would like to get it done sooner than later so it all blows up in my face I have time to come crawling back to the forum for help .

Thanks for the input all, keep it coming, going to go out and crawl under the jeep today and take a look around.
The Captain is a one eyed Dwarf, who's throwing dice along the wharf. In the land of the blind the one eyed man is King. - Tom Waits
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Old 04-08-2012, 12:11 PM   #5
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I am pondering this issue myself, there are large pieces of cat. (I assume) in my muffler, or my muffler is coming apart. I have passed recent EI. But would like to upgrade to a full high flow exhaust system in near future. Has anyone done a "Complete" upgrade? Any prices or suggestions?, From cylinder head back. Are the manifolds worth replacing? Or just cat, muffler, and piping.
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