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Damaged exhaust after header

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Old 06-20-2014, 07:46 PM
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Default Damaged exhaust after header





How badly has this been affecting my mpg/performance?

Been like this the last two years that I have owned it.

Looks like the hulk pinched it with his finger and thumb definitely restricting it by half.

*some nice high res pics, makes me wonder what my 4k pics would look like.

Last edited by crabmushrooms5; 06-20-2014 at 07:48 PM.
Old 06-20-2014, 08:09 PM
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Default Standard.

Noticed this same thing on mine when I first got it about 5 years Ago. Had the muffler shop fix it with new tube when I had my cat back put on.

One wheeling trip later (or regular driving, I have no idea) and it looked the exact same. I've given up at this point. Im not a doctor but I'm 60% confident that 90% of XJs have this issue.

-Alex
Old 06-20-2014, 08:11 PM
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It's normal. They come from the factory like that.
Old 06-20-2014, 08:14 PM
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It's that way to help heat the catalytic converter up.
Old 06-20-2014, 08:15 PM
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Originally Posted by RTorrez1
It's normal. They come from the factory like that.


So there is no excuse for getting performance/new headers and exhaust?

my 100th Post!!

Last edited by crabmushrooms5; 06-20-2014 at 08:19 PM.
Old 06-21-2014, 12:23 AM
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it's a great excuse for a better downpipe. you can find them without the crush in it.
Old 06-21-2014, 07:31 AM
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No crush is great and works great.

Be aware though that if you get a downpipe with no crush, and it's the same basic shape as the original, you could whack it with your driveshaft.
I have mine made by the local muffler shop and he tucks them up tighter than the factory routed them.
Old 06-21-2014, 12:51 PM
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Originally Posted by cruiser54
No crush is great and works great.

Be aware though that if you get a downpipe with no crush, and it's the same basic shape as the original, you could whack it with your driveshaft.
I have mine made by the local muffler shop and he tucks them up tighter than the factory routed them.
I've recalled you mentioning this. Something about using two 45° bends instead of the stock 90° one?
Old 06-21-2014, 04:51 PM
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Originally Posted by cruiser54
No crush is great and works great.

Be aware though that if you get a downpipe with no crush, and it's the same basic shape as the original, you could whack it with your driveshaft.
I have mine made by the local muffler shop and he tucks them up tighter than the factory routed them.
I would go to a shop but I am tired of contributing to leeches and parasites trying to find a mechanic with matching morals.
Old 06-21-2014, 11:03 PM
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Originally Posted by 1991Jeep_Man
I've recalled you mentioning this. Something about using two 45° bends instead of the stock 90° one?
Yes.
Old 06-22-2014, 12:18 AM
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The "crushed" area is for driveshaft clearance on a bone stock, un-lifted XJ.
Old 06-22-2014, 09:26 AM
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Originally Posted by SeriousOffroad
The "crushed" area is for driveshaft clearance on a bone stock, un-lifted XJ.
Nope. Disguised as such per my buddy in Jeep Engineering. Really there, along with the area above the crossmember and before muffler and cat, to slow down the exhaust and get the cat working sooner.
Old 06-22-2014, 09:39 AM
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Originally Posted by cruiser54
Nope. Disguised as such per my buddy in Jeep Engineering. Really there, along with the area above the crossmember and before muffler and cat, to slow down the exhaust and get the cat working sooner.
So I'm safe without the "crush"? I would like it to run maybe an inch further from the oil pan, looks like I have enough clearance between oil pan and driveshaft to make this happen.

Plan on replacing headers all the way back, don't want loud maybe just a little rumble though. If I could go completely silent, I would do that

Last edited by crabmushrooms5; 06-22-2014 at 09:44 AM.
Old 06-22-2014, 09:49 AM
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Originally Posted by crabmushrooms5
So I'm safe without the "crush"? I would like it to run maybe an inch further from the oil pan, looks like I have enough clearance between oil pan and driveshaft to make this happen.

Plan on replacing headers all the way back, don't want loud maybe just a little rumble though. If I could go completely silent, I would do that
"Safe"? Whaddya mean? I know a good muffler shop can make one that won't hit. as for off the shelf, unless you're lifted over 3", I'd be concerned.
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