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Installing a new Cat-back exhaust
Installing a new Cat-back exhaust
All Jeeps equipped with exhaust
Published by TerryMason
11-19-2005
Installing a new Cat-back exhaust

For some time now, my CJ's exhaust system had been rusted through. It had gotten so bad that new Rancho shock in the rear was black from the smoke that it took on a daily basis. Virginia's state inspection finally convinced me to replace it (more accurately, the rejection sticker did the job). Here are the steps I went through to install my new exhaust system (including audio of the finished product).


Audio files

I had thought about using new stainless steel setup, but I could never get an accurate description of the sound that it would produce. I decided to make recordings of the before and after sounds so that everyone else could check them out. I used an IBM thinkpad's built-in microphone, and sat the laptop next to the driver's side rear tire. I you can send in recordings of your exhaust, please forward them to the message board.


Stock system (with hole in muffler)
This is the original system. Although it sounds beefy, it was really about as loud as not having a muffler at all.


New Walker muffler
You can definitely tell the difference between the two mufflers. Now, I can carry on a conversation with my passengers.
 
By TerryMason on 01-25-2008, 10:41 PM
Step 1

This is my stock muffler, you can see that rust had rotted it all the way through. The best tool you can use in this upgrade is by far a grinder. Using the grinder, I began by cutting off all the exhaust clamps. They were far too rusted to even think of wrenching them off.
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installing-new-cat-back-exhaust-fd801039.jpg  
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By TerryMason on 01-25-2008, 10:43 PM
Step 2

After getting all the clamps off, I discovered that I still couldn't pull the muffler off. I used my grinder to cut a line in the muffler (see the picture) making sure not to cut through the pipe from the catalytic converter. Then, using an old screwdriver and a hammer, I peeled back the old muffler like a banana. This process ended up working nicely.
Attached Thumbnails
installing-new-cat-back-exhaust-fd801043.jpg  
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By TerryMason on 01-25-2008, 10:44 PM
Step 3

After the old system is out, you should assemble the new system on the ground, and finger tighten the blots. Then put the entire system in place and tighten everything up.
Attached Thumbnails
installing-new-cat-back-exhaust-fd801046.jpg  
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By TerryMason on 01-25-2008, 10:46 PM
Step 4

It sure is nice to have that nice shinny tail pipe again!
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installing-new-cat-back-exhaust-fd801047.jpg  
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By TerryMason on 01-25-2008, 10:51 PM
Before and after

Before and after
Attached Thumbnails
installing-new-cat-back-exhaust-fd801044.jpg  installing-new-cat-back-exhaust-fd801045.jpg  
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