Jeep Cherokee Forum

Jeep Cherokee 1997-2001: Exhaust Modifications

Here are a few points to consider in making modifications to your exhaust system's catalytic converter, muffler, and tailpipe.

By Jon LeSage - October 14, 2015

This article applies to the Jeep Cherokee XJ (1997-2001).

Modifying the exhaust system on your Jeep Cherokee adds to performance, both in terms of power and the way it sounds when you’re driving. Modifying the system can boost exhaust flow to increase torque and horsepower. It improves acceleration, maximum hill climbing, towing and passing power. The right exhaust system modification also offers you the choice of maintaining a mellow performance tone or going to a deep aggressive tone, depending on your preferences.

#1 Catalytic Converter

DIY Cost – $70

Professional Cost – $150 for labor, plus cost of part

Skill Level – Difficult; replacing the converter can be simple, but there are complications that can come from OBD-II O2 sensors.

You should be able to get an OEM-style replacement at any parts store. However, if you're seeing the "Check Engine" light, there could be a problem in your OBD-II O2 sensor system. The O2 sensor might be sending codes to the OBD-II system that will run a richer mix of fuel than it should have. That could mean getting worse gas mileage. You always have the option of welding in new parts to fix the problem, but taking your Jeep into a good exhaust shop might be a better way to go. Recommended for its OEM-style replacement, but you will need to be vigilant of the O2 sensor system.

#2 Muffler

DIY Cost – $80

Professional Cost – $200, plus cost of part

Skill Level – Moderate; this will require some experience and understanding of how the exhaust system works.

Finding the right muffler has a lot to do with the tone coming from your Jeep. It can be a fairly easy job to do yourself. You may need to bend the metal hanger on the tailpipe to get it back in line, but don’t pound the muffler with a hammer because that could break it. As for replacing clamps, make sure your new part is a lap joint clamp and not butt joint. Recommended for its fairly easy installation and sound.

#3 Tailpipe

DIY Cost – $120

Pro Cost – $200-$300

Skill Level – Moderate; you may be able to slide the muffler into the pipe easily; however, if there’s a lot of rust involved, it will take more cleaning tools and time spent.

You're probably going to work with clamps and tools for a 2.25" exhaust system. You can slide the muffler on top of the pipe. There is a protruding piece at the bottom of the front pipe. Cut out the notch that accepts that piece on the muffler to ensure they slide together correctly. If the pipes and exhaust system are completely rusted out, you may save money finding a repair shop that can do the work for a reasonable price. Recommended for its easy installation, but it might get harder if it is rusted.

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