installing new exhaust system on my 95 and under inspection of the old one I noticed the downpipe is dented quite a bit. curious I looked into it and got two answers of how/why it is. one is that it's factory spec for clearance reasons the other is that it's from the front axle smacking it and causing a dent..... I still don't know so which is it?

most off all if you have done a new exhaust with a new downpipe how did it work out clearance. any issues there? if it is an issue with the front axle would a flex joint in that spot work so I don't get the same dented in my new pipe......maybe just another reason to finally get around to that lift I've been itching to do

The dent is supposed to be there. It's for driveshft clearance with stock suspension and stock ride height.

Another theory is that the dent is there to slow the exhaust flow down and help heat the catalytic converter.

Not a theory. It was indeed done to get a waiver from teh EPA on emissions, to heat the cat, and was "disguised" as clearance for the front shaft.

Re-route the front pipe, eliminating the "crush" and feel the difference in power.

Where can I get this front pipe, and "difference in power"???

Supporting documentation?

No documentation except what I was told by a friend in JeepTech who worked on emissions compliance as one part of his job at AMC. I was Service Manager and Shop Foreman at a Jeep dealer from 1980 through 1992 and worked with him during that time.

I have my local muffler shop make and install it. If you're lifted 3" or higher, you can use the standard routing. If not, the muffler guy needs to route it away from the shaft. Kinda like making a pipe with two 45s instead on one 90* bend.

do you have a picture of the new path?? and what bout jute putting a flexpipe section there.....

I would like to see some pics too.

the theory behind the epa and the dent may be realisitic...
part # 54448 says "federal emmissions" on my cpu at napa
without the fed emmisions- part # 55277

the other one might be cali emissions...

Flexpipe would last about 2 weeks AND probably anger the o2 sensors(s) as wonky flexpipe won't seal up tight no matter WHAT you did. It would leak before falling off.

Now I finaly know where the H those dents come from.
As far as flex pipe goes, the only place it belongs is on the parts house shelf. I used to be in the mini-truckin scene back in the day so I was constantly killing crossover pipes. The longest time flex worked for a patch was about 3 days

Wonder if a muff shop could cut it (at the red line), expand it and re-weld it?