The butt connectors are a huge source of electrical resistance compared to soldering. And, they get worse over time.

 

For 1996, there is a recall and free replacement for the converter. Not sure about your 93. But the following may be relevant. It is regarding the 1993 XJ.

Manufacturer: CHRYSLER CORPORATION
SUMMARY:
DURING ASSEMBLY OF THE FRAME, A FILLET WELD THAT JOINS THE INNER STEERING GEAR ATTACHMENT REINFORCEMENT TO THE FRAME RAIL, WAS OMITTED.

CONSEQUENCE:
DUE TO HIGH STEERING LOAD EVENTS, VEHICLES CAN EXHIBIT BROKEN STEERING GEAR ATTACHING BOLTS OR FRAME RAIL CRACKING AT THE STEERING GEAR ATTACHING POINT INCREASING THE RISK OF A VEHICLE CRASH.

REMEDY:
DEALERS WILL INSPECT THE VEHICLES FOR CRACKS IN THE FRAME RAIL. VEHICLES THAT SHOW CRACKS WILL BE EQUIPPED WITH REINFORCEMENT PLATES. VEHICLES THAT ARE FOUND TO BE FREE OF CRACKS WILL HAVE A SLOT CUT IN THE CROSS MEMBER AND THE FILLET WELD WILL BE ADDED.

NOTES:
OWNER NOTIFICATION: OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING MAY 1997. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

 

Now that we're talking about catalytic converters... My 90 XJ doesn't have one, and I'm not sure it ever did.

Being that as it may, should I consider adding one to my exhaust system?

Does the presence of a converter have an effect on the way the module controls the engine?

 

yes. It should have one on it. It ll tremendously help the engine run better

 

Not on a Renix will it help it run better.

 

Is the 99+ intake swap worth it on a 97? I don't know if years really matter, just curious if it's worth the hassle?

I have a 62mm bored TB on the way, and have plans to upgrade the exhaust from the headers back. Or at least get rid of the dimple in the down pipe for a little better flow.

 

it is not that hard to do. I would do it while replacing the gasket.

 

Right, but is it ultimately worth it?

I figured if it really is a solid upgrade, I would get the necessary parts to make that swap when I get around to upgrading my header/exhaust.

 

to me it is

 

Good luck finding a definitive answer, let us know if you do. lol

From FourWheeler magazine;
'99-Up Horseshoe Intake
Myth: According to that great wealth of information that is never wrong, the Internet says you'll get a 5-30hp gain thanks to the '99-up 4.0L's swooped, equal length runners and larger plenum volume.
Our Thoughts: While a free-flow intake manifold can deliver more power, it's only going to allow as much air to flow as the cylinder head and camshaft will call for. Upping the intake runner volume too much will cause the intake charge to lose velocity, killing low- and mid-speed power and torque. On a '98-earlier engine running a stock camshaft and unported cylinder head, it's wasted effort.
Claimed Gains: 5-30hp
Actual Gains: 5hp loss on Trasborg's '98 XJ (Project Mileage Master)

 

Interesting read. So now I need to ask... did you do the upgrade?

 

Yes.. lol

 

and...?

 

and according to FourWheeler I should reinstall the stock 96 manifold.