1996 XJ 4.0 I6 5 Spd 4X4

So I have been having this noise when starting at, a rattle if you will. Now I have sort of isolated it to the exhaust system.

If I give the CAT a light kick I can duplicate the noise so it is in the exhaust system.

Currently the clamps and hangers look like crap, and the muffler has at least one small leak.

However it seems the noise may be internal to the CAT.

At this point since I am attempting to do a partial restoration on this XJ I figure it is a waste of time and money to replace only one piece of the exhaust.

I'd like to replace at least everything from the manifold joint back.

Is there anyone marketing a complete stainless system including a CAT?

It would be nice if the new system had hangers attached to mount up as the OEM system did.

Thanks

 

I googled tail pipes and came up with full systems. look up magnaflow they have full systems, or look at the rockauto.com catalog they have it, idk about stainless steel though, but i know they have aluminum pipes

 

and if the noise is in the cat its because the brick crumbled. if I were you i would just get the cat, muffler and tail (if u even need a new one), cheapest and most efficient way to fix your problem.

Or just replace the cat and spend the money on more important things, the leak in the muffler wont effect performance

 

I hear quite a few people like magnaflow. Don't know if they make a cat back stainless system, though.

 

I am gonna look into where the noise is exactly, but at first glance it's like it may be in the CAT. Not throwing any codes 'yet'.

The rattle I hear is when first engaging the clutch, so at lower rpm, lower frequency ... when you increase speed it settles out.

I may pull the CAT out and shake it, but before I go through that I'll check for other things loose.

Just odd that when I stuck my leg under and kicked the CAT I heard the same rattle.

If I have to replace the CAT, makes sense just to do it all in one shot. The rest of the exhaust, hangars, clamps, in addition to the muffler look like crap. Heck a month ago one muffler clamp crumbled when I tapped it, the others look only slightly better.



EDIT: OUCH ---- Stainless is OUT !!!

Looks like the CAT is gonna be $100 - $120

 

If your gonna replace the whole exhAust are you looking for a stock replacement or something with a little more rumble? Flowmaster is what i have on mine and it sounds great. As for the cat I would do stainless magnaflow it the best out there a little pricey but deff one of the best out there. It might take more work to. Get a custom one made like other people said there are kits Gibson makes a good one so does magnaflow and one the forum mud frog makes some awesome ones for a great price look in the vendor part of the forum.