Exhaust System Replacement - JeepForum.com
 
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post #1 of 6 Old 10-23-2015, 02:49 PM Thread Starter
Moosewop
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1999 XJ Cherokee 
 
Join Date: Jun 2015
Location: Grand Rapids
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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!

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post #2 of 6 Old 10-23-2015, 03:12 PM
mschi772
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1997 XJ Cherokee 
 
Join Date: Apr 2012
Location: Racine
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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/
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post #3 of 6 Old 10-23-2015, 03:58 PM Thread Starter
Moosewop
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Thank you, this was super helpful.
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post #4 of 6 Old 10-23-2015, 06:22 PM
FISTFULL
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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.
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post #5 of 6 Old 10-24-2015, 12:09 PM
Robert_B
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Quote:
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
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post #6 of 6 Old 09-06-2016, 08:02 PM
cpttuna
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1998 XJ Cherokee 
 
Join Date: Jul 2004
Location: napoleon ohio
Posts: 200
all stainless $320 in parts $40 for 1 hour labor fabricating. Borla muffler, universal CAT 304 ss pipe from recycling center.
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