Do I need anything else? Looks like there are 3 hangers I will be replacing as well. Cat up to the manifold looks good. Rubber piece for the hanger looks good. Am I missing anything?

98 xj 4.0

 

sounds like you've got it covered.

get stock replacements for proper lengths.

 

Thanks. Yes, going all stock.

 

I can't seem to get the old muffler separated from the Cat. I've heated it and used a BFH. Any suggestions?

 

Soak in Kroil or PB Blaster today. Soak again tomorrow. Again the next day. Then try it again.

If all else fails, use an angle grinder with a cutoff wheel.

 

Cut the pipe off behind the cat leaving the original cat outlet and the offending connector pipe still there. Then you can work it carefully with a cut-off disk parallel with the pipe to cut through the outer pipe while leaving the cat outlet intact. Once you do that you may be able chisel and pry the old pipe off the cat outlet.

I'm sure there are many techniques used for this type of repair depending on the skill level and tool arsenal of each. I generally take my exhaust work to a local shop who does good work at a very fair price. It's just not a fun job. Rust in the eyes can ruin your day.

 

IIRC, we used a Dremel to cut a couple of horizontal slits in the muff tip. Hammer and chisel spread the tip a little more and off she came.

 

What Orlo said...that's the way I do it also. It saves time and knuckles..

You can buy a cheapo 4 inch grinder at Harbor Freight for around 20 bucks, and a pack of 4 inch cut-off wheels for under 10 bucks. And you will find many other uses for that stuff too..
And don't forget safety glasses !

 

Thanks for the suggestions everyone. I ended up using my angle grinder and cut a slit in it and then hammer and chisel it apart.

 

i let nature do the work for me. I started up the jeep one cold morning and it blew apart. win.

 

Mine fell off on the highway 3 hours from home. That was a noisy drive!

 

I did mine the easy way took it to a muffler shop and had them replace everything including the hangers and a lifetime warranty muffler (house brand)..........Cost $91.28 out the door, to cheap to fool with at home.

 

When I was searching the site, I came across a post of yours that mentioned this. I wasn't going to find those prices up here in North Jersey. And the parts alone cost me $125. Went with Walker muffler and pipe.

But I'm glad to do it myself and it was pretty easy once I got the muffler off. That was about a 15 min delay.

 

To extend the time to your next muffler / tailpipe replacement, do these 2 things:

1) Use stainless steel clamps. I think 3 are needed.

2) Before installing, spray a can of hot paint INSIDE the muffler and tailpipe until all inner surfaces are coated. Then coat the outside of the parts after scuffing them with scotch brite. This will stink on your first run, but will slow down rusting from the inside which is why these parts die so quickly.

This is an alternative to a stainless steel pipe and muffler which would cost you about $1000.

 

Anything past the y pipe/crossover pipe on really any vehicle is really easy, just wear safety glasses and drink plenty of beer, and use an angle grinder/large flathead and a hammer as needed to split old pipe off the cat/muffler, and don't overtighten clamps.

A lot of guys here always recommend going to a shop, but they never understand the prices we pay up here in the tristate.