all muffler and exhaust questions go here!!!!!!
No, I don't lick fish.



Joined: Mar 2011
Posts: 11,169
Likes: 26
From: Northern Kentucky
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0
Im new to this site, but have owned and own a number of other jeeps. question I have is re: a 96 2 dr Cherokee sport 4. HO. I acquired it last fall and it I drive it a LOT--2500+ miles/month for my work ---mostly highway miles. I am looking to maximize efficiency and since I spend a lot of hours in the jeep--typically a couple hundred per working day. I'm looking at various improvements that will make the jeep more driver friendly since I spend almost as many hours driving it as I do sleeping.
I find that the raspy drone of the existing muffler is very tiring. It has a low restriction Cat system put on by the PO but the muffler really grates on the nerves after a few hours on the road.
From what I have seen on the site here the Dyno-max Super Turbo seems to be highly recommended. However not all of us judge quality by the same standards. some "recommended" mufflers are for power at any cost to sound levels, and some at the other extreme are for absolute minimal noise. I don't mind a little bit of a growl but want to avoid a snarling drone. I have a long fast 3000 mile road trip coming up in another month or two And I'd really like to get the exhaust a bit more comfortable without paying a penalty in reduced mileage. comments and suggestions are most welcome.
I find that the raspy drone of the existing muffler is very tiring. It has a low restriction Cat system put on by the PO but the muffler really grates on the nerves after a few hours on the road.
From what I have seen on the site here the Dyno-max Super Turbo seems to be highly recommended. However not all of us judge quality by the same standards. some "recommended" mufflers are for power at any cost to sound levels, and some at the other extreme are for absolute minimal noise. I don't mind a little bit of a growl but want to avoid a snarling drone. I have a long fast 3000 mile road trip coming up in another month or two And I'd really like to get the exhaust a bit more comfortable without paying a penalty in reduced mileage. comments and suggestions are most welcome.
I don't have any interior soundbytes of it, but here's an exterior video of how it sounds. Keep in mind, the most the engine was at was about 3500 rpms and that's about the only point you can hear anything, but I never heard any interior drone from the muffler. Only thing I could ever really hear was drone from my intake during hard acceleration
Looking to upgrade my exhaust. I want to get better mpg and get a meaner sound.
Thinking I should get a highflow cat, new header and new muffler. Suggestions? 2.5 vs 2.25 pipe?
What should I do here?
Thinking I should get a highflow cat, new header and new muffler. Suggestions? 2.5 vs 2.25 pipe?
What should I do here?
No, I don't lick fish.



Joined: Mar 2011
Posts: 11,169
Likes: 26
From: Northern Kentucky
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0
Magnaflow high-flow cat, 2.5" pipe, and Flowmaster Super 44 muffler are a great combination for just what you're after.
Hey Bass, my prerogative for not supporting slavery and sweatshops is one that everyone should have, just look at it in terms of what if it were you or your family. But yeah I think it may have been Dynomax's data that I looked at, but I remember looking at other comparisons, and dynomax beat the comparible flowmaster , even some sights have people calling them slowmasters. It's a good sounding muffler that flows better than stock, period. not so loud that the cops get after you or the neighbors hate you either. No I am not buying the parts new, I have a 99 that I am junking, so I am robbing everything I can get out of it, and like I said my 97's exhaust is smaller diameter before the cat and through the 90 degree bend, the 99 for free is the logical solution. And you've never heard a manifold leak that sounds like a knock or hammering? Well I mean I can't help that you haven't been around much, and also if a manifold were to crack, but you can't hear it, can't detect it, who cares? a crack that let anything out would make noise, to say it wouldn't is silly, it's physics man. With the 99 exhaust I do have to make mods on the o2 sensor wiring, but other than that it looks like it will work ok, and the 99 intake is worth it if it saves gas mileage, or adds a small increase in power especially if I have to tear everything down already. I am not building a race car here, but do like to optimize what I have, if I have the stuff available, and there are jeeps everywhere right now that people can get these parts for , for next to nothing, junkyards in this area will not even buy them right now, they have so many. Not everyone has hundreds of extra dollars to just buy new stuff always, and there is plenty of chances to get these items for almost nothing, so why not take advantage? I wouldn't buy a borla header for 600 either if you think the intake that's almost free is a waste of time , then a 600 dollar buy and all that work certainly is, even a 129 dollar buy is not worth it. If I wanted big performance gains I would strip the wiring completely , put a homemade 340 set up in it and be done with it. That could be done pretty easy as well with a 5.2 and 5.9 engine that you swapped parts around on. In fact I have a 96 as well with a 5.2 that was ran out of oil by the previous owner that I have plans on doing something with like that, but keeping the electronic system, I just have to pay close attention to timing issues and such. A better flowing intake isn't worth the effort to you but a header is? that logic just doesn't make much sense to me, not that I don't like headers , but they just don't bring much gain for the effort and price. What I am doing isn't going to make me do wheelies either, but my jeep will be on the road again and I can afford it.
No, I don't lick fish.



Joined: Mar 2011
Posts: 11,169
Likes: 26
From: Northern Kentucky
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0
As far as Magnaflow vs. Flowmaster... honestly it all boils down to personal choice. If it was a newer v6 motor on say a Jeep JK or a Nissan Frontier, the Magnaflow sounds perfect, for an old v8 or even our hefty-sounding straight 6s, the flowmaster sounds much better to my ears.
I've not seen any non-proprietary data that shows better performance of one vs. the other... especially not on a stock and/or high-mileage low-compression motor.
The magnaflow catalytic vs. the flowmaster catalytic comes from a recommendation from a trusted friend here on the forums.
Senior Member
Joined: Jun 2014
Posts: 925
Likes: 6
From: Eagle River, Alaska
Year: 1999
Model: Cherokee (XJ)
Im new to this site, but have owned and own a number of other jeeps. question I have is re: a 96 2 dr Cherokee sport 4. HO. I acquired it last fall and it I drive it a LOT--2500+ miles/month for my work ---mostly highway miles. I am looking to maximize efficiency and since I spend a lot of hours in the jeep--typically a couple hundred per working day. I'm looking at various improvements that will make the jeep more driver friendly since I spend almost as many hours driving it as I do sleeping.
I find that the raspy drone of the existing muffler is very tiring. It has a low restriction Cat system put on by the PO but the muffler really grates on the nerves after a few hours on the road.
From what I have seen on the site here the Dyno-max Super Turbo seems to be highly recommended. However not all of us judge quality by the same standards. some "recommended" mufflers are for power at any cost to sound levels, and some at the other extreme are for absolute minimal noise. I don't mind a little bit of a growl but want to avoid a snarling drone. I have a long fast 3000 mile road trip coming up in another month or two And I'd really like to get the exhaust a bit more comfortable without paying a penalty in reduced mileage. comments and suggestions are most welcome.
I find that the raspy drone of the existing muffler is very tiring. It has a low restriction Cat system put on by the PO but the muffler really grates on the nerves after a few hours on the road.
From what I have seen on the site here the Dyno-max Super Turbo seems to be highly recommended. However not all of us judge quality by the same standards. some "recommended" mufflers are for power at any cost to sound levels, and some at the other extreme are for absolute minimal noise. I don't mind a little bit of a growl but want to avoid a snarling drone. I have a long fast 3000 mile road trip coming up in another month or two And I'd really like to get the exhaust a bit more comfortable without paying a penalty in reduced mileage. comments and suggestions are most welcome.
I looked at them headers , and some even cheaper on amazon , ebay and summit, but they are made in china, so I did not buy them out of principal. But being made in china, they can't be trusted to really be stainless, or a good metal alloy, or even made right. They could crack and break or not fit, it's a risk buying anything made in china. They could run thousands of parts on a broken line and not care, sure you would get a refund from whoever sold it to you, but you would still be out time and other money. If you haven't noticed , suppliers try to hide the fact that stuff they sell is made in china, and are very reluctant to tell you even if you ask. There was one header that looked just like a Borla, cost 129, but after hearing it was Chinese I did not want it. I have to agree with most on here, that a header is a waste of money and often does not even outflow the stock manifold that the jeep engineers made. You know they wanted a good vehicle built and the exhaust manifolds can't really be altered to much, unless you go out the hood or something. What I am saying is they would have had no production cost savings by not making a good flowing exhaust manifold, but after the down pipe a lot can be done if you can get bends smoother and bigger, lose back pressure with a better cat and muffler, and tail pipe. I'm waiting on someone to throw a turbo on a 4.0 or better yet a supercharger. I personally am going to try to use a 99+ exhaust on my 97, seems more open. And the Dynomax super turbo muffler I got is not real loud but it flows better than a flow master.
This laptop is probably made in china. Its about 5 or 6 years old now, trust me I tried to find one made in usa, but the big corporations sold us out and use cheap labor to make stuff, yet still charge the price as if it were made here. Some of the components are made here in the USA, like I think the last time I replaced the hard drive I found one made in usa, but I can't say for sure. I try hard to not buy from countries with bad labor practices. My old new balance shoes are about to fall apart, I can't find a pair I like that are made here. But it's funny when people cry about the economy, then buy foreign goods, I mean where do people think jobs come from? I like a free market also, but when a ceo can make billions and rig the market in his favor to stomp out competition that is no longer a free market. People have to support their community and country, it can't be left up to some lying politician to make some sort of magic trick to save us, we have to do it ourselves and elect politicians to work for us, not us work for them
It makes me sick to my stomach that our big companies that grew up here and make money here want to sell us out so they can be so powerful and rich that they can't even spend the money, and they try to say it was hard work, and they did it on their own and what not, but that is such an untrue myth , without the infrastructure, grants, and tons of support they would be nothing.
But yeah I search long and hard every time I buy anything to try to buy US made stuff. I go without until I can afford stuff, I want to support my countrymen so perhaps they can return the favor, unfortunately most people do not. Sometimes it isn't about saving a dollar today at wallmart , but what happens tomorrow and the options you have being destroyed.
So I don't mean to get political on this JEEP sight, which is a USA American thing, and I know it isn't the right place, and I apologize to the ADMIN, I was asked a question, and had to answer. Unlike most people I do care about others and effects of what we all do, and try to take personal responsibility like everyone should. I don't just leave it up to others to keep us going. Now we are so deep , the question I am responding to brings up a good point, you can't even find a lot of stuff made here anymore, our money is all fake, our country is gutted. Just like the banking tricks and schemes this country as a whole has turned into the same and it is doomed, living on artificial means mostly that will eventually crash just like the banking schemes, but when the country crashes their will not be taxpayers to bail it out since we are that country. Whatever , ban me if you want, I don't care, I answered truthfully to a smart *** punk question.
It makes me sick to my stomach that our big companies that grew up here and make money here want to sell us out so they can be so powerful and rich that they can't even spend the money, and they try to say it was hard work, and they did it on their own and what not, but that is such an untrue myth , without the infrastructure, grants, and tons of support they would be nothing.
But yeah I search long and hard every time I buy anything to try to buy US made stuff. I go without until I can afford stuff, I want to support my countrymen so perhaps they can return the favor, unfortunately most people do not. Sometimes it isn't about saving a dollar today at wallmart , but what happens tomorrow and the options you have being destroyed.
So I don't mean to get political on this JEEP sight, which is a USA American thing, and I know it isn't the right place, and I apologize to the ADMIN, I was asked a question, and had to answer. Unlike most people I do care about others and effects of what we all do, and try to take personal responsibility like everyone should. I don't just leave it up to others to keep us going. Now we are so deep , the question I am responding to brings up a good point, you can't even find a lot of stuff made here anymore, our money is all fake, our country is gutted. Just like the banking tricks and schemes this country as a whole has turned into the same and it is doomed, living on artificial means mostly that will eventually crash just like the banking schemes, but when the country crashes their will not be taxpayers to bail it out since we are that country. Whatever , ban me if you want, I don't care, I answered truthfully to a smart *** punk question.
Junior Member
Joined: Aug 2015
Posts: 55
Likes: 0
From: SW MI Lake-effect snowbelt country
Year: 1996
Model: Cherokee
Engine: 4.0 HO
PLEASE!!!!!!, I joined here for information about improving my jeep to meet my individual needs. I have no use for socio-political rants and personal attacks and other litter-box crap. lets keep on topic take the crap to another forum somewhere else.
CF Veteran




Joined: Jul 2012
Posts: 3,136
Likes: 360
From: Andover, VT
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0 L
Forgive me if this has been covered in the last 291 pages of this thread but I'd like to discuss the pros and cons of 2.25" vs 2.5" in different locations of the exhaust. Certain points I'm interested in are flow rates, power gains, exhaust tone, and how loud it would be.
Let's be hypothetical and pretend said jeep has cowl intake, 62mm TB, headers, a not crushed downpipe, and high-flow from there back.
I'm assuming most headers collect at 2.25". Is this true? Would the ideal setup keep 2.25" right up to the cat or open up to 2.5" in the downpipe?
Would it be better to keep 2.25" all the way up to the muffler and 2.5" out, or 2.5" up to the muffler and 2.25" out? Or just either one the whole way?
The goal is a low throaty tone that isn't rediculously loud and is centered mostly around low-end torque gains.
Let's be hypothetical and pretend said jeep has cowl intake, 62mm TB, headers, a not crushed downpipe, and high-flow from there back.
I'm assuming most headers collect at 2.25". Is this true? Would the ideal setup keep 2.25" right up to the cat or open up to 2.5" in the downpipe?
Would it be better to keep 2.25" all the way up to the muffler and 2.5" out, or 2.5" up to the muffler and 2.25" out? Or just either one the whole way?
The goal is a low throaty tone that isn't rediculously loud and is centered mostly around low-end torque gains.
Last edited by XJlimitedx99; Aug 11, 2015 at 10:10 AM.
If one wanted to overhaul the exhaust from the header back (excluding headers) with 2.5 inch piping, hi-flow cat and muffler, what kind of issues will be had with the O2 sensors? I have a 2001 which from what I understand has 4. My main concerns are the pre-cat and post cat sensors. Do I need to get a catalytic converter that can accept O2 sensors? If not, are these accounted for in exhaust upgrades?
Ok I have one for the expert, I swapped a 99 intake and exhaust manifold to a 97, it painstakingly bolted up, but upon starting it is very loud, I looked under it and it looked like I have about a quarter inch gaps in the bottoms of the exhaust ports that isn't contained. are the heads really different that much? I had tried to match it up to the gasket and it seemed to be a fit, I really can't see on the outer pipes and ports, did I do something wrong and force it down? I know my down pipes aren't really looking even as far as being tightened up equally, but it wouldn't seem like that would allow me to bolt them up then if it forced it, it was really hard to find the holes in the middle, and that is where I can see the gaps, I just can't see that well under there. It could just be something that will not work with the brackets on the manifold. I had mentioned this before about the swap, one guy said he wasn't sure if it would work since the heads had changed some , I wish I had a set of each side by side. I sure am hoping I did something wrong and this can be an easy fix without cutting or welding, or just cutting, for clearance. No one really knew either way so I guess when this gets figured out for sure we have the answer. I used the 99 plus exhaust manifold since my cat had broken off in the front, and I had this 99 to use from a junk vehicle, I think the pipe is bigger from the down pipe to the cat, it was better for sure, and the two downpipes are obviously bigger, and the manifolds were needed to run to them. So I really needed to do the swap to be able to not buy a cat and get some value out of the 99 that I lost my *** on. It wasn't about performance gain, but I did expect a better flowing exhaust in the end. It really isn't as loud and popping as I would have thought for having the ports open air, and revving it it seems even quitter, maybe it's just the gasket, I used the one from the 97, as it was thicker and seemed better, the one from the 99 is just thin metal. Are the header part numbers different from the 98 to 99? That was a ton of work for a bad result , but I hope I can save it somehow, otherwise with cutting/welding, I may as well have bought a cat, lol and had the exhaust replaced from manifold to cat
So does anyone here have any input?
So does anyone here have any input?


