Connect New Muffler with Tailpipe (pics)
 

Hi all,
2001 XJ, 4wd, 4.0, 202K miles.

I'm replacing muffler which is rusted through a few spots and the top seam is loose.

I ordered a new one from RockAuto (Walker quiet flow ss (see pic)).

On front, it looks like all I have to do is unbolt the flange connection between cat and muffler.

On rear, it looks like I need to cut tailpipe as close to muffler as possible (will use angle grinder).

3 questions:

1. Can I just bolt flange connection back up or is there some sort of seal/gasket I need to replace?

2. Does the new muffler output pipe slip over the tailpipe? If so, I have exhaust clamps to tighten up.

3. If I use exhaust clamp on output of muffler, do I need to worry about a good seal...is there any goop/sealant I have to apply or just crank down on clamp?

A correct size band clamp can make installation really quick, simple and leak free. Available thru Jeg's/Summit.

Don't know about flange connection. My '96 didn't have one.
Maybe there's a donut gasket in there.
But the outlet should slide over t-pipe.

Just a flare no donut, band clamp will work if both pipes are the same O.D. That factory pipe may just turn to dust when you start playing with it.

The band clamp in the pic I post is a lap joint band clamp.....it's for 2 different sizes of pipe. U can see 1/2 of the clamp is slightly larger/smaller than the other 1/2. The tail pipe slips inside the muff nipple.

A butt joint band clamp is for clamping 2 pieces of the same size pipe together.

Better pic.