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 Post subject: HOW TO: MUFFLER SWAP
PostPosted: Fri Jan 07, 2011 8:08 pm 
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The muffler I put in is a Thrush Welded, 2.5" center inlet, 2.5" offset outlet. That is the spec on the KK, so if you are using any other brand, you need the same: 2.5" center inlet, 2.5" offset outlet.
Image
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Tools: reciprocating saw w metal blade or hacksaw (I used a hacksaw, it wasn't that bad)
Socket/ratchet, 5/8 iirc
Heavy dead blow hammer
3pcs 2.5" u bolt style muffler clamps
2.5" i.d. extension tube, flared at one end. The size you need will depend on the length of your new muffler.

Ok, first measure the length of your new muffler and write that down. After your old muffler is cut out, you are left with a 32" gap between the two stock pipes. I overlapped my 3 joints 2", which means you need 38" of new muffler and extension. So the formula is:
38 minus length of new muffler= length of extension you need. The thrush muffler is 19", so I needed a 19" extension piece to make 38". I bought a 24" extension, so obviously i had to cut it to 19".

Step 1: set parking brake and jack up rear of vehicle and put on jackstands. Block the front wheels. Put on safety glasses or goggles.
2: cut the pipe behind you old muffler, if you have enough space, it may be helpful to place a jackstand or block of wood under the muffler, its heavier than it looks.
3: once you cut the pipe, loosen the nut on the factory clamp in front of the muffler. Try twisting that muffler off. If you cant twist/pull it off, use your dead blow and hammer it off.
4: it may be helpful to smear some motor oil on the stock pipes to make installation easier.
Now slide your new muffler on either of the two stock pipes. I put mine on the foreward pipe. Now slide the non flared part of the extension in to the muffler, and the flared part over the stock pipe. Remember, 2" overlaps at all three seams.
5: clamp it all down tight until you see pipes crimp a little bit.
6: now piss off your neighbors with your mean sounding jeep 8)

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Last edited by At The Helm on Thu Oct 27, 2011 11:33 pm, edited 3 times in total.

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 Post subject: Re: How to: change your muffler
PostPosted: Wed Jan 12, 2011 5:08 pm 
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Will be attempting this soon. Thanks

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 Post subject: Re: How to: change your muffler
PostPosted: Wed Jan 12, 2011 5:13 pm 
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Great write up............but...........your not welding it on so not so great. sorry

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 Post subject: Re: How to: change your muffler
PostPosted: Wed Jan 12, 2011 7:33 pm 
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I chose not to weld it on in case I crush it or tear a hole in it. The clamps hold it on nice and tight and will make for a fast and easy swap if I need to. :JEEPIN:

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 Post subject: Re: How to: change your muffler
PostPosted: Fri Jan 14, 2011 4:46 pm 
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i'm going to weld mine on at work so yeah :)

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 Post subject: Re: How to: change your muffler
PostPosted: Sun May 01, 2011 4:36 pm 
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Good write-up. I installed a Super 44 which is only 13" length. I ended up only needing an 18" exhaust tube though (and I even had to cut it 2"). I'm not sure how you ended up with the 38" necessary.

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edit: image reference

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 Post subject: Re: How to: change your muffler
PostPosted: Sun May 01, 2011 7:34 pm 
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The 44 is 19" overall length, 13" case length, just like the thrush. Are you sure you didnt get a 24" extension? I dont see how that would fit especially if you cut off the original clamp in front of your muffler.

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 Post subject: Re: How to: change your muffler
PostPosted: Mon May 02, 2011 9:08 am 
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Atthehelm wrote:
The 44 is 19" overall length, 13" case length, just like the thrush.


That makes more sense...

For the muffler removal I just cut as close as I could to the front and the back to get the muffler out of the way, then I took an impact wrench to the front clamp and a hammer to knock the rusted tubing off. In that picture it kind of looks like I just cut it straight off at the clamp but I slid it off of the pipe.

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 Post subject: Re: How to: change your muffler
PostPosted: Sat Jun 18, 2011 6:13 pm 
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does any one know how to remove the resonator?

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 Post subject: Re: How to: change your muffler
PostPosted: Sun Jun 19, 2011 12:34 pm 
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Looks like you just cut it off and remove the hanger. You'll probably want to replace it with a straight pipe and a tip or turndown and weld the hanger back on.

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 Post subject: Re: How to: change your muffler
PostPosted: Thu Jul 21, 2011 12:39 pm 
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^^^^ :roll:
Like this:
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 Post subject: Re: How to: change your muffler
PostPosted: Tue Jul 26, 2011 7:53 pm 
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remdawg wrote:
Good write-up. I installed a Super 44 which is only 13" length. I ended up only needing an 18" exhaust tube though (and I even had to cut it 2"). I'm not sure how you ended up with the 38" necessary.

Image

edit: image reference



Just so im not buying the wrong thing here, all i should need is the muffler with the right size and location in/outlets and clamps and maybe some extra piping??? so about 100 bucks if that..... am i correct,, i dont need these 2-300 dollar setups


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 Post subject: How to: change your muffler
PostPosted: Thu Jul 28, 2011 9:44 pm 
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glsec507 wrote:
Just so im not buying the wrong thing here, all i should need is the muffler with the right size and location in/outlets and clamps and maybe some extra piping??? so about 100 bucks if that..... am i correct,, i dont need these 2-300 dollar setups


Correct. I got the 18" tubing from auto zone as well as the three clamps. I will warn that I've noticed it's beginning to rattle. I've tightened the clamps down which fixed it temporarily but it's starting again. I will probably just end up getting it welded since it's kind of embarrassing/ghetto to drive past people with rattling exhaust.

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 Post subject: Re: How to: change your muffler
PostPosted: Mon Aug 01, 2011 9:53 pm 
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remdawg wrote:
glsec507 wrote:
Just so im not buying the wrong thing here, all i should need is the muffler with the right size and location in/outlets and clamps and maybe some extra piping??? so about 100 bucks if that..... am i correct,, i dont need these 2-300 dollar setups


Correct. I got the 18" tubing from auto zone as well as the three clamps. I will warn that I've noticed it's beginning to rattle. I've tightened the clamps down which fixed it temporarily but it's starting again. I will probably just end up getting it welded since it's kind of embarrassing/ghetto to drive past people with rattling exhaust.


You're from Rochester, its perfectly acceptable to have a ghetto exhaust! I just moved to Seattle from there

And on topic, I just got a quote to have a new exhaust welded on my KK and it's only going to be $100. IMO it's worth it to not have to put up with constantly tightening the clamps.

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 Post subject: Re: HOW TO: MUFFLER SWAP
PostPosted: Tue Mar 19, 2019 3:10 pm 
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I just recently did this muffler swap, and followed the instructions to the T, and it made the install very easy. Thank you, and its fun annoying neighbors now.


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