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Unread 03-31-2010, 08:08 PM   #1
AmnWatkins
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1994 YJ Wrangler 
 
Join Date: Aug 2008
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Questions About Replacing Cat

I've been trying to get my '94 to pass IM for a little while now, and I need to replace the Cat. The first step is an obvious one when you look underneath the body, removing the skid plate. While obvious, it's not as easy as I thought it would be to achieve. I started out with spraying the 6 bolts down with PB Blaster the same way start any job on the Jeep. I removed the four corner bolts then used a jack to support the skid plate as I took out the two remaining bolts. That done I slowly lowered the jack and to my surprise it didn't fall off the jack like I was expecting it to do. Instead I saw my drive shaft, T-case, and a few other items lower with the skid plate. I quickly stopped the jack and raised it back up a bit till I could take a look at the Cat to ensure it was in fact bad (it is). Upon that confirmation I noticed I had to run to work (I was planning on leaving the skid plate off till I replaced the cat) so I buttoned everything back together and took off.

My question to you guys is what are the steps to removing the skid plate so I can replace the Cat? Also is the stock Cat just bolted in or should I just take it to a shop *shudder*?

Thanks

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Unread 03-31-2010, 08:41 PM   #2
ugmo
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Buy a cat online, have a muffler shop weld it in. Call for welding quotes first. If someone asks too many questions or wants to give an estimate in person then they're trying to reel you in.
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Unread 03-31-2010, 09:17 PM   #3
Burnerman
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You need to remove the transmission mount bolts and torque arm bushing nut from the skid plate. The skid plate is the only thing holding the trans and transfer case up. You'll need to support the trans when you drop the skid.
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Unread 03-31-2010, 10:44 PM   #4
AmnWatkins
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Okay, i'll call around town. How much should this cost about? I've never had to take any of my vehicles in to a shop except for when i was 16 and my alternator went on my 89 Cheerokee and it cost me like $400. After that i've done all work for myself. So on average what does it cost to get one welded in by a shop if i have a Cat in hand?

Thanks
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Unread 03-31-2010, 11:44 PM   #5
moonshinefuel
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I had mine done today. One guy wanted 170 dollars for labor, two other shops wanted 70 dollars for labor, then finally found a small shop that did it for 55 dollars. That is the price ranges I encountered today.
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Unread 03-31-2010, 11:56 PM   #6
AmnWatkins
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I can do $55. Is it possible to do this myself in the garage with standard hand tools? I know they sell bolt in Cats, is the stock one just bolted in or do i need to cut it out? Thanks.
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Unread 04-01-2010, 12:34 AM   #7
moonshinefuel
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The original cat is bolted in. If yours still has the bolts, then you want to buy a "direct fit" cat. If it is welded in then you will just simply buy the cat with without bolt mounting flanges, just open pipe, and have it welded in. But yea if yours has bolts, just do it yourself, sure.
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Unread 04-21-2010, 10:50 PM   #8
AmnWatkins
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I know it's been awhile, and i'm still in the same boat as before, which is trying to replace my catalytic converter. I have a direct fit cat that i got from shucks and it's just sitting around (I picked up a Bushmaster AR-15 and it's kinda taken over for a bit) and i plan on trying my hand at it again tomorrow now that i have the correct part.

In any case when you're looking up at the cat on either end where it conects to the exhaust pipes you can see a notch in the pipe and then a little stud that keeps the cat from rotating or moving back and forth, effectivly making removal quiet difficult. Does anyone have any ideas on how to pull the cat off then put one back in? I'm only an E-3 and money is tight.

any help is greatly appreciatd (and needed).

Thanks
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Unread 04-22-2010, 05:33 AM   #9
ROADDOG516
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I just replaced mine with a flowmaster high performance cat that was a bolt on. After removing the skid plate I supported the tranny and tc with jack stands. (note: becareful with the transmission stabilizer stud if its old it could break , mine did got another one with much needed poly bushings for $11.00 from 4wd.com) I originally thought my YJ still had the factory cat which was welded on, I grinded off this weld so that I didnt have to cut the pipe (i didnt want to shorten my pipe), after cleaning up the pipe I bolted on my new cat and clamped everything down dam tight. The only pain was that the "direct fit" cat had a slightly larger diameter outlet than my muffler would recieve so I used a muffler pipe expander and opened it up. Buttuned it all back together and couldnt be happier with results. Just by replacing my cat I got back my 5th gear and have great fuel economy even with my 4banger and 33's. As I said I thought I had the factory cat but when I brought it to the scarp yard the guy showed me that this thing was a aftermarket which explains why it was welded on. O well he still gave me five bucks better than zero. good luck.
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Unread 04-22-2010, 05:40 AM   #10
ROADDOG516
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By the way I did all of the above in my garage in about 5hrs, but I have torches and lots of tools, total cost approx 100 bucks including muffler, not including time=money.
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Unread 04-22-2010, 05:39 PM   #11
AmnWatkins
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Thanks. Mine is factory, or at least not welded on. I think i have to push it off till the weekend seeing how heavens decided Alsaka needs more snow at the end of April. FML.

Thanks again
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Unread 04-22-2010, 06:19 PM   #12
mongowo
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Quote:
Originally Posted by AmnWatkins View Post
Thanks. Mine is factory, or at least not welded on. I think i have to push it off till the weekend seeing how heavens decided Alsaka needs more snow at the end of April. FML.

Thanks again
watkins, if your AF or Army then check and see if you guys have auto self help shop, the guys who work there have tools and will help you and it is really cheap. If you were down here near Ft Lewis McChord, I would let you bring it to my house and we would knock it out!. If you do it yourself, use a propane torch to heat the pipes so that they expand and help to get the rust broken apart just a little bit so you can slide it off!!
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Unread 04-22-2010, 06:28 PM   #13
ZeroGravity
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Can anyone confirm that factory cats were bolted in?

I bought my catalytic converter from Eastman for about $80 shipped (high flow, OE fit). I originally bolted it but I was sick of adapters and leaks so I welded it in.

The good thing about exhaust work, is that it's exhaust work. If you can't get something to come out, cut it out. Chances are it's either too rusty to be re used anyways, or wasn't coming out any other way.
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Unread 04-22-2010, 06:40 PM   #14
mongowo
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Quote:
Originally Posted by Couchrider View Post
Can anyone confirm that factory cats were bolted in?

I bought my catalytic converter from Eastman for about $80 shipped (high flow, OE fit). I originally bolted it but I was sick of adapters and leaks so I welded it in.

The good thing about exhaust work, is that it's exhaust work. If you can't get something to come out, cut it out. Chances are it's either too rusty to be re used anyways, or wasn't coming out any other way.
ya couchrider, mine is a bolt in. When I put a new clutch and slave cylinder in my 92 me and the pops in law tore out all the exhaust from the downtube back and it was all bolt on clamps, and I know mine is all stock. since then I had my flowmaster exhaust removed and had a new muffler put on that is closer to stock. The shop I go to gives me a screaming deal, 115.00 for everything, it's welded in and all has a lifetime warrenty!!!
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Unread 04-22-2010, 06:48 PM   #15
ZeroGravity
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Are the tubes joined by a flange or exhaust clamp?
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