Exhaust System Replacement - JeepForum.com
LinkBack Thread Tools
post #1 of 6 Old 10-23-2015, 03:49 PM Thread Starter
Registered User
1999 XJ Cherokee 
Join Date: Jun 2015
Location: Grand Rapids
Posts: 12
Exhaust System Replacement

Noob question. I'm replacing my exhaust system as it's rusted out and cracked between the muffler and cat. I'm thinking of buying the Dynomax Ultra Flo Welded Muffler with a 2.25 in and out. If I have a 2.5 in converter, will I still be able to mount it with the clamps? Does everything have to be 2.25? I'm also open to suggestions for cheap cats, as I'm thinking about replacing it while I'm under there. I have no idea what the previous owner put in, and I want to make sure everything fits. Thanks!

Moosewop is offline  
Sponsored Links
post #2 of 6 Old 10-23-2015, 04:12 PM
Registered User
mschi772's Avatar
1997 XJ Cherokee 
Join Date: Apr 2012
Location: Racine
Posts: 3,346
If it is 2.5" out on the cat, you can get a reducer to put between the cat and muffler for a few bucks that will reduce from 2.5 to 2.25. Clamps have always been fine for me.

Performance-curve.com is a fantastic source for quality cats that are very cheap. Scrap your old cat yourself if you can (it's difficult some places to do this especially if you can't prove that it was YOUR cat)--factory cats can scrap for as much as $30 or more depending on the area.

If you want to take it a step FURTHER, you can get a new downpipe from Rockauto or wherever really by Walker for like $40-50.

If your header isn't cracked, my recommended cheap exhaust replacement is:
  • Walker downpipe ($50)
  • NGK O2 sensors ($60)
  • Cat from Performance-Curve.com ($60-80 depending on what you want)
  • Dynomax Super Turbo cat-back ($150; $50-75 rebates happen annually...Spring usually I think)
Stick with 2.25"

If your header is cracked, Dorman makes a great, cheap OEM replacement.

Build Thread -- https://www.jeepforum.com/forum/f177/whats-chrokeese-build-thread-2525690/
mschi772 is offline  
post #3 of 6 Old 10-23-2015, 04:58 PM Thread Starter
Registered User
1999 XJ Cherokee 
Join Date: Jun 2015
Location: Grand Rapids
Posts: 12
Thank you, this was super helpful.
Moosewop is offline  
post #4 of 6 Old 10-23-2015, 07:22 PM
Registered User
1999 XJ Cherokee 
Join Date: May 2007
Location: Alex, VA
Posts: 565
2nd the dorman manifold recommendation. It was a perfect fit.

99 Sport, 3.5" lift mixed parts.32" BFG ATs.JCR front and rear bumpers.Skids, lights,&usual stuff.
FISTFULL is offline  
post #5 of 6 Old 10-24-2015, 01:09 PM
Registered User
Join Date: Jun 2015
Location: Blairsville
Posts: 128
Originally Posted by Moosewop View Post
Thank you, this was super helpful.
Yeah, thanks mschi772.

'99 XJ Sport 4x4 4.0
'15 WK2 Overland 4x4 5.7
Robert_B is offline  
post #6 of 6 Old 09-06-2016, 09:02 PM
Registered User
1998 XJ Cherokee 
Join Date: Jul 2004
Location: napoleon ohio
Posts: 214
all stainless $320 in parts $40 for 1 hour labor fabricating. Borla muffler, universal CAT 304 ss pipe from recycling center.
Attached Thumbnails
Attached Images
cpttuna is offline  

advice , exhaust , exhaust system , xj

Quick Reply

Register Now

In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome