I have never replaced my catalytic converter and exhaust (though I bought used, but I still assume not) and my jeep has around 200k miles on it, largely runs good but recently started having some exhaust issues. I tracked the issue down to the pipe going into the exhaust was failing, and I put some thermal concrete stuff and it seems to work for now. But...I know the whole thing needs to be replaced likely.

I live in a state where we dont have any sort of emissions check, and I also dont want this thing loud. I simply want an efficient system that maybe might improve power or mpg (again not at cost of being super loud).

Can I just cut off the cat completely, or does it do anything positive (if it spews black smoke I'll get it, dont want to pollute) and 2ndly, can I literally just put the tailpipe right on the end of the muffler (rather than have it piped all the way to the back?)

I do not have welding equipment so ideally looking for some sort of bolt on or at least band-clamp like adapters. What is the cheapest way I can pull this whole thing off, given what I said and my options? Thanks guys

 

Legally, you can't remove the cat completely. Pretty sure it's a federal law.

I replaced the entire exhaust, manifold back on my '95 and I think it was roughly $400 - the most expensive parts being the manifold and cat. If you're just interested in the cat back, you can replace the pipes and cat with regular retail parts store products for no more than ~$200 in parts.
I'm really happy with my exhaust replacement. I didn't do any welding (everything is clamped) and my Jeep is nice and quiet and fully legal - even though due to the age, I don't need an emissions test to get my inspection sticker.

 

Cut the old off with a sawzall, replace the cat with another or just run straight pipe. Without the cat, the exhaust will smell more, and pollute more, if thats a concern of yours. Keeping a working cat keeps everyone happy, even if you dont have emissions testing. Your call, of course. You can use an adapter on either end and some muffler clamps. Or, if you can find the proper size, you can use sleeves to join both pipes. No welding required. Make sure its solid all the way around. One of these things.

 

Dont cut the cat off. Cuts down on emissions and noxious gas emissions which is good for your lungs and the planet. And it's federally illegal to do so

I would buy a new exhaust from Performance Curve, they have a pre-bent catback kit for the XJ. Buy one of those, a standard replacement catalytic converter and have a local exhaust shop weld it up. Make sure you inspect the header for cracks!

 

What about the issue of skipping all the piping to have it out the back of the jeep rather than right off the muffler?

 

You like a vehicle with an obnoxious drone?

 

I ran no cat, with a cherry bomb high flow muffler for 8 years when I lived in KY. Ran great, felt like it was breathing well, but the gas mileage sucked. Moved back home where there are strict emissions tests, and had to get a cat and o2 sensors, mileage went up by like 3-4. But I did lose some pep.

BTW, fb97xj1 those couplings have saved my *** before, and all I had was a pair of channel locks...

 

Running without a cat should not make your mpg lower there is 2 o2 sensors one before and one after the cat, the one before the cat is what helps with your fuel/air mixture and the cat doesn't affect that since it is downstream of the sensor. The one after the cat is only to monitor the cat and doesn't affect your fuel/air mixture, the only thing it may do is set off a check engine light if you remove the cat. I don't have one on mine and it doesn't give me any issues and the exhaust smell is the same as any other gas engine.

 

Carbon monoxide is an odorless, colorless gas can kill you. I prefer to run all my exhaust systems as designed all the way to the rear bumper.

 

I know this is the reason, but I am skeptical that it matters. Esp if 'my' pipe is out the back, but the guy in front of me is shooting his pipe straight at me so I dont think my exposure is going to change much.

To be clear, I am saying use a new cat, then a new muffler and then put an exhaust pipe right on the muffler.

 

I'm of the same mind as TurboXJ - I prefer to keep it stock with the proper components. I don't like to screw around with my own, or my passengers' safety - especially when those passengers may be my kids. IMO any "road vehicle" (in other words, unless it's a true "mud truck" that you never, ever drive on the road) should have a proper and leak free exhaust.

It IS illegal to remove your cat - if you live in a state that does routine vehicle inspections, you will get in trouble if you have no cat. That said, it's your Jeep and your own situation and decision. For those that choose to remove theirs,... well, that's none of my business and it is what it is and to each their own.

Seriously, the system is cat - muffler - tailpipe. Aftermarket replacement tailpipes are like $35 and are bent correctly for the location, mufflers are the same and the local Advance Auto had the parts in stock! It's not even worth the time and energy to screw around with a half-assed mickey mouse fix. Even if you need to replace hangers and the such it's like $5-10. My time alone makes it inconceivable to deal with trying to re-route the exhaust - but again, if you insist, it's your Jeep so do what you'd like.

 

I'm almost certain that the 96 is like the 95. The cat connects to the muffler and there's a single longer tailpipe from the muffler to the rear. It should have one hanger that uses the standard rubber-type isolator and then at the end there's a rubber circle with a tab that is welded. The rubber hanger is bolted to the frame, so you can remove it and use a universal hanger or do what I did and grab a u-bolt and a rubber plug that fits in the circle from the hardware store and make your own.

The advantage of getting the OEM replacement components is that the muffler pipes connect directly to the cat and tailpipe without dealing with adapters. Before I replaced my cracked manifold, I had tried to fit the muffler to the old cat, but getting the rusty. bent/dinged cat piping to connect with the new muffler was a PITA. I spent hours dealing with adapters and sealants and ended up cutting up an adapter to make it fit and it still was questionable. Once I got the new cat, front pipe and manifold it all went together beautifully (no welding, all clamps) and is smooth and quiet.

 

If your vehicle is hermetically sealed then you might be OK. Problem is when a vehicle is in motion a low pressure area is created inside the passenger compartment/trunk. Pressures attempt to equalize so that outside air is forced inside any opening in the body, most of which on an old Cherokee are in the floor and quarter panels. You get a little dose they claim that symptoms kinda feel like the flu, you get a little more who knows, probably dead. The case of the vehicle near you the concentration of CO becomes almost negligible almost instantly due to the large volume of air between you and the source.
Investigate some Physics and Science courses and see if your opinion remains unchanged.

 

Just do a Flowmaster High Flow Cat and I added the Banks Cat Back Exhaust. Perfect fitment. Even extra length to the piping on both so you can cut to your liking to make fit perfectly. Performance gains were not my goal with it. Just inexpensive. But it does sound pretty good and it was only $102 for the cat and $284 for the exhaust.

 

I also have a 96 XJ Country. When I bought it I immediately asked Jeep for a build sheet and registered with them as the new owner. Not long after I received a recall notice from Jeep re: the catalytic converter and that the recall on the cat had not been performed by the previous owner(s). The cat was making a rattling noise and had been for years. Jeep said on the form to bring it in to a dealer for assessment. They would determine as to whether or not it needed replacement. I put it off for several years, in fact about eight and I was worried it might not still be in effect. I called Jeep and they said yes the recall was still in effect so I made an appointment and finally took it in. They replaced the cat for free because of the recall. You might give jeep a call to see if the recall applies to your XJ if it still has the original cat. Maybe you will get a free one as well.