99 Sahara 4.0 exhaust - JeepForum.com
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post #1 of 5 Old 09-18-2019, 03:20 PM Thread Starter
CO_crawler
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99 Sahara 4.0 exhaust

So I failed inspection. Manifold connector bolts were loose and just broke one off as they are rusted as can be. Guess I will have to drill them out? The entire exhaust is just moving around with about 1/2 gap between that front connection.

The muffler is rusted through and both rear hangers are broken off. I measured the muffler:

5"height
20" length
10" wide
inlet pipe 2.5"
outlet pipe 2"
rear tailpipe 2"

Whats the cheapest replacement? I read most TJ's have 2.25 inlet/oulet and I also don't have the bolted connection between the cat and the muffler just a clamp. The muffler shows the chrysler emblem....

I was looking at a magna flow 10416 and trying to grab a j bend to dump before the rear axle. I will need a new hanger....suggestions?

Thanks
CO


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post #2 of 5 Old 09-19-2019, 12:25 AM
TheBoogieman
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Thrush welded muffler for $30-35.
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Quote:
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post #3 of 5 Old 09-19-2019, 01:34 PM Thread Starter
CO_crawler
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Quote:
Originally Posted by TheBoogieman View Post
Thrush welded muffler for $30-35.
Are they all just universal fit? I've never had to do any exhaust related things. I see 17651 but its got a 2.25 inlet and output. I've currently got a 2.5 in and 2 out. how can I fit the inlet or do I need to find a 2.5 inlet model?

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post #4 of 5 Old 09-19-2019, 04:58 PM Thread Starter
CO_crawler
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Arrrghhhhh!!!!

Just snapped off a flange stud. Looks like it is pressed in....

So I was checking out the thrush models on auto zone and it shows that i need the 2.25" model but I measured mine and its 2.5 so looking at the 17650. Is that the proper way to size a universal muffler by the size pipe??

Anyone else also have a TJ w 2.5" inlet and 2" outlet? I am ok with going 2.5 for my new tailpipe if that is acceptable...

Anybody with thoughts please feel free to chime in. Thanks
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post #5 of 5 Old 09-20-2019, 01:59 AM
Jonny Jeep
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The studs should be theaded. UNF on the head side, UNC on the outside. There is normally a short unthreaded section between the two threads which might be why it would seem like it's pushed in. Parts list confirms. Studs are 3/8"-16 / 3/8"-24 x 1.75" long.


Actually I guess you don't mean those ones, you mean the ones in the manifold to exhaust flange, I think? I seem to remamber they are pressed in. I drilled mine out after they rotted and one snapped, replacing them with nuts and bolts instead.
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