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Old 02-09-2011, 05:57 PM
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Unhappy Muffler problem ~ need assistance

Hi

After quite a lot of hassle removing the old tailpipe thanks to just having some axle stand, I have just fitted a brand new Rugged Ridge muffler and tail pipe on to my 98 Sahara. It sounds a lot better, the problem I have is that the exhaust blowing slightly around the connection between CAT and muffler and is blowing quite badly when it connects on to the tailpipe. Is this just poor fitting and does this mean I need to re-jiggle the system, or do I need to something else to effectively pack the holes? Not done this before, so need your help.


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Old 02-09-2011, 06:43 PM   #2
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Did the pipes bottom in the fittings and did you tighten them enough with the CORRECT DIAMETER clamps?

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Old 02-09-2011, 09:42 PM   #3
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If they are the correct diameter, aka, they came with the kit, then maybe you need to tighten em up a little more. Or, maybe you didnt push the male side into the female side enough. I couldnt say that without it sounding dirty, can I get a "Thats what she said?!" lol but seriously, check it.
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Old 02-10-2011, 04:44 AM   #4
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Get somebody to weld the pipes together...25-30 bucks.
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Old 02-10-2011, 05:06 AM   #5
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I agree with ^ clamps strech when they get hot then cold even whe tou get it to seal it will loosen up in time welding it gets it done and over with.
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Old 02-10-2011, 08:19 AM   #6
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When ever I do exhaust work of any kind I only use the clamps to hold things together until I weld them in, theirs no way a modern clamp and exhaust system will ever stay tight unless you torque the hell out of it and use a sealer, unless you use stainless, and even that is welded nowadays. "back in the day" pipes would stay with only a clamp or two, but modern pipes is substandard compared to the old stuff.
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Old 02-10-2011, 09:08 AM
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Thanks for all the advice. It just seems a little crazy that the muffler and tailpipe from the same manufacturer do not fit very well. The tailpipe slides in the muffler (almost sounds wrong that!!) with the base of the tailpipe sitting on the base of the muffler. One suggestion from one of my work colleagues was to cut the muffler outlet, and 12 o'clock, 3, 6 and 9 o'clock and make an inch insertion at all 4 places, this should then allow the clamp to really clamp on the tailpipe and prevet gaps.
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Old 02-12-2011, 05:15 PM
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I went with the suggestion of cutting each end of the muffler connection with a 150mm cut and 12 oclocl, 3, 6 and 9. Fitted the tailpip again, and afte a lot of huffin and puffin, got it all set up with blowing.
Sound sgreat, not too loud, especially on road at 50+

Overal really happy with the end result.

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Old 02-12-2011, 05:33 PM   #9
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I'm glad you got it on man, Cutting the pipe is a great way to get them to fit right, just keep an eye on it to make sure theirs no leaks that develop later on.
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Old 02-13-2011, 02:46 AM
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Thanks Ken. Will do. I'd not heard a Rugged Ridge muffler so was a little concerned as to the possible noise. I guess it might get a little louder when it settles in, but now, its great. You can't really hear much on the open road sitting at 60mph, slower speeds and back roads, it sounds great.

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Old 02-13-2011, 10:32 AM   #11
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Your welcome man, I tell everybody that clamps a exhaust system the same thing cause carbon monoxide is dangerous even with the top off.
As far as noise, don;t be too concerned as long as you don;t sound like one of those little lowered pos junk cars with the ground effects and boom boom subwoffers that make you wonder if your bumper just fell off.

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