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Unread 03-09-2011, 07:25 PM   #1
t3553r
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1996 XJ Cherokee 
 
Join Date: Mar 2011
Location: New York, New York
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EXHAUST WON'T FIT! (1996 Jeep Cherokee)

okay so first of heres some background info

The Car:
1996 Jeep Cherokee 4.0L 4WD

The Parts:
autozone maremont tail pipe
autozone super-c muffler

The Problem:
According to autozone the above parts are OEM fit which I understood to mean they should fit with any issues...Unfortunately for me the tailpipe and both ends of the exhaust pipe are 2 1/4" meaning the tailpipe doesn't slip over the muffler or vice versa. On the cat side I have the same problem...the muffler and cat have the same diameter hole and thus I cannot slip the cat over the muffler...Could someone please enlighten me as to how this is supposed to be done? I was under the impression this wasn't welded as the microfiche show clamps holding it on. Is autozones computer simply wrong and these parts are the wrong diameter? Any help is much appreciated!


Last edited by t3553r; 03-09-2011 at 08:23 PM..
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Unread 03-10-2011, 06:59 AM   #2
hyperboarder
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1992 XJ Cherokee 
 
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Couldn't you just use a 2-1/4" coupler with some clamps? Seems doable.
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Unread 03-10-2011, 08:06 AM   #3
dukie564
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1995 XJ Cherokee 
 
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they sell adapters to do this without welding, which is how I did mine. Get them so one end fits over the upstream pipe, and fits into the downstream one. You will need 2 clamps per splice point.

like this:
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1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 283,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/project-danger-cart-xj-1297118/
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Unread 03-10-2011, 09:13 AM   #4
Jeep_Runner_83
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1998 XJ Cherokee 
 
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you could rent a tailpipe expander from autozone to widen the openings just enough to slip on. not sure of the cost but that and a 3/8s rachet is what ya need and when put the clamps use an impact. if ya don't have one available get it has tight as possible and recheck after a couple of days to see if u can tighten it any more. having a connection come loose after a bump and your miles from a store sucks.
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Unread 03-10-2011, 09:16 AM   #5
dukie564
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oooooh Harbor Freight sells those cheap also
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1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 283,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/project-danger-cart-xj-1297118/
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Unread 03-10-2011, 09:42 AM   #6
t3553r
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1996 XJ Cherokee 
 
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Location: New York, New York
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hmm sounds like the coupler / pipe expander is my best bet...as far as what pipes should be bigger I assume it's as follows:

Muffler should slide OVER the cat, tailpipe should slide OVER the muffler?
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Unread 03-10-2011, 09:48 AM   #7
dukie564
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Location: Hanover, MD, Maryland
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righto
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1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 283,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/project-danger-cart-xj-1297118/
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Unread 03-12-2011, 12:33 PM   #8
t3553r
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1996 XJ Cherokee 
 
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thanks worked like a charm...for anyone wondering what couplers to get for the parts listed above its 2" - 2 1/8"
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