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Old 12-27-2008, 03:24 PM   #1
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Changing a Muffler on a TJ

WHAT A PAIN IN THE BUTT!!! I grossly underestimated this project.

Sorry, just had to vent.

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Old 12-27-2008, 03:48 PM   #2
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What was so hard about it? I have never done it on a jeep but it has got to be easier then my stang. I mean the jeep for one doesn't even need to be jacked up! Please explain!!!

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Old 12-27-2008, 04:08 PM   #3
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i had a few issues when i installed my cat-back. with the older tj's you need to cut the pipe in between the muffler and cat, and with the newer jt's its just a bolton muffler.
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Old 12-27-2008, 04:30 PM   #4
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What brand did you get? I need a new one on my 98. I am thinking flowmaster.
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Old 12-27-2008, 04:43 PM   #5
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i got a deal on a banks monster car-back for my '99, for the amount of power gain i think most cat-backs are over priced. i got my cat-back for $100 off. the banks brings the pipes up to a 2.5" from the stock 2.25". i have batter gas millage and more power in 2nd and 3rd gear. and gained 3-4 HP.
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Old 12-27-2008, 05:00 PM   #6
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I've replaced the exhaust on my Mustang too. I put a mid muffler system on my Mustang, dual exhaust, and changed the H-pipe, and moved the mufflers from the stock axle back position to on either side of the driveshaft. That took a couple of hours, this TJ exhaust has taken all freakin' day and caused a trip to the auto parts store. Mine's a 98 TJ. Had to cut the pipe between the cat and muffler. Then, in order to get the old muffler out I had to cut it between the muffler and over axle pipe. Put the new muffler in place and found out that my first cut was too close to the muffler and had to make a 3rd cut closer to the cat because of the different diameter of pipes. Now, apparantly that cut wasn't correct because the overaxle pipe is too short and won't meet up w/ the muffler. I got this kit off e-bay. Oops, my bad. It's a flowmaster 40 series muffler. Should at least sound good when done.
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Old 12-27-2008, 05:50 PM   #7
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it won't sound too bad. is it the black muffler made of diamond plate? my install took 2 hours to finish. one of the hanger broke off the frame so i had to weld it back on, i wasn't paying close attention and welded it in the wrong place so i had to cut it off and re-weld it back on in the right spot.
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Old 12-27-2008, 06:15 PM   #8
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Plain black, no diamond plate. (?)
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Old 12-27-2008, 06:23 PM   #9
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there are a few flowmaster 40 or 44 mufflers that were made of black diamond plate, someone had installed one and said it was crap and that he ended up getting a different flowmaster.
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Old 12-27-2008, 08:11 PM   #10
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Yeah, just got it on. It sounds OK. Nothing special. Not loud, but no 'rumble' like I was hoping for. It sounds nice and smooth, almost like a European sports car. Finally done. Just took it for a test drive, no leaks, just a little rattle where the muffler is sitting too close to a heat shield. That'll be a quick, easy fix in the morning once the exhaust cools down. Yea, done!
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Old 12-27-2008, 09:10 PM   #11
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Quote:
Originally Posted by 05GT-O.C.D. View Post
Yeah, just got it on. It sounds OK. Nothing special. Not loud, but no 'rumble' like I was hoping for. It sounds nice and smooth, almost like a European sports car.
So are you driving a 2.5L?

The 40 series sounds pretty good on a 4.0L. No Euro speak here?
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Old 12-27-2008, 10:35 PM   #12
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So are you driving a 2.5L?

The 40 series sounds pretty good on a 4.0L. No Euro speak here?
Nope, it's a 4.0L. I got impatient and put some gloves on and bent that heat shield. Just took it for a drive. Rattle's gone! When I say Euro, I mean that as a pretty good thing. I'm just used to a V8 Mustang GT and V8 Commander... so the 6 just doesn't have that burbly rumble (plus a Harley). I'm happy with it, just wish I knew I would've had to cut the old exhaust off the cat, then cut again to get it over the axle... and to make the cat-muffler cut clean I also had to drop the skid plate. Does anyone know why there's those 4 extra bolts in the middle that hang the skid plate to that rubber isolater? Heck, you'd think the 6 bolts built into the frame rails would be enough. I understand the isolater being there, I just wasn't expecting the extra bolts.
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Old 12-27-2008, 10:43 PM   #13
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Those 4 bolts ,bolted to the skid is what your trans/t-case is supported and held in buy.

If you remove the four nuts you can lift the whole drive line. The Isolator is the trans mount.
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Old 12-27-2008, 10:58 PM   #14
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Aaah, that makes sense. I was doing all this with a wet undercarriage and a flashlight. Couldn't see all that well. I'm guessing that having the skid plate hanging by just those 4 bolts isn't the best thing in the world? I removed the outer 6 without knowing the inner four were there. So, the skid plate hung for a little bit until I could get some jack stands under it.

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