Muffler Pictures

long_tall_texan · **Posted:** Wed Apr 29, 2009 12:15 am

Same concept should apply. May just have to improvise a little. Not sure if the Exhaust diameter and routing are the same.

riptricket · **Posted:** Wed Apr 29, 2009 12:16 am

So no welding???

long_tall_texan · **Posted:** Wed Apr 29, 2009 12:24 am

Nope. I did not weld at all. TJKJ did, but I wanted to be able to re-use the intermediate pipe for other possible muffler options down the road. Yes, there is a ever so slight exhaust leak where I cut the slits in the in and out tubes. But not a problem. Passed inspection with no problems.

0311_DoC · **Posted:** Sun May 03, 2009 8:55 pm

long_tall_texan wrote:

0311_DoC wrote:

So just the intermediate pipe and the muffler is all you need? no additional hardware?

What you need:

I Muffler
1 intermediate Pipe
1 turndown exhaust tip
2 2.5" exhaust clamps

First, use a hack saw and cut a slit about an inch or so long on input and output tubes of the muffler. You will have 2 slits on either side of each tube. The arrow is pointing to the slit in the pic below. This gives you a small amount that the clamps can pull together without crushing the tubes. Then down the road, if you want to switch mufflers, you can re-use the intermediate pipe and the turndown.

Next insert the intermediate pipe into the muffler input. Tighten it down with a clamp. Do the same thing on the output end of the muffler with the turndown.

Then just bolt the whole thing up to the stock flange. No need for a gasket. No need for a rear hanger either. It is plenty sturdy without a rear hanger.

I went to summit to look around, do I need exhaust clamps or muffler clamps? they appear to be different

0311_DoC · **Posted:** Sun May 03, 2009 9:01 pm

long_tall_texan wrote:

Nope. I did not weld at all. TJKJ did, but I wanted to be able to re-use the intermediate pipe for other possible muffler options down the road. Yes, there is a ever so slight exhaust leak where I cut the slits in the in and out tubes. But not a problem. Passed inspection with no problems.

so when u all did this to your exhaust you just left the muffler near the cat but did not use the pipes all the way to the rear of KJ right? just a tip directly off the muffler?

Robbrez · **Posted:** Sun May 03, 2009 9:05 pm

0311_DoC wrote:

long_tall_texan wrote:

Nope. I did not weld at all. TJKJ did, but I wanted to be able to re-use the intermediate pipe for other possible muffler options down the road. Yes, there is a ever so slight exhaust leak where I cut the slits in the in and out tubes. But not a problem. Passed inspection with no problems.

so when u all did this to your exhaust you just left the muffler near the cat but did not use the pipes all the way to the rear of KJ right? just a tip directly off the muffler?

when i buy mine this week hopefully i am not going to dump it right down ...i dont like the idea of all the fumes under the car sitting at a light or something
im going to get some more pipe to fill the gap after the muffler because the flowmaster is about 13 inches shorter i believe and just clamp it together to the preexisting pipe

but it seems that a lot of folks just dump it right down after the muffler ..i personally dont like the idea

Robbrez · **Posted:** Sun May 03, 2009 9:08 pm

0311_DoC wrote:

long_tall_texan wrote:

0311_DoC wrote:

So just the intermediate pipe and the muffler is all you need? no additional hardware?

What you need:

I Muffler
1 intermediate Pipe
1 turndown exhaust tip
2 2.5" exhaust clamps

First, use a hack saw and cut a slit about an inch or so long on input and output tubes of the muffler. You will have 2 slits on either side of each tube. The arrow is pointing to the slit in the pic below. This gives you a small amount that the clamps can pull together without crushing the tubes. Then down the road, if you want to switch mufflers, you can re-use the intermediate pipe and the turndown.

Next insert the intermediate pipe into the muffler input. Tighten it down with a clamp. Do the same thing on the output end of the muffler with the turndown.

Then just bolt the whole thing up to the stock flange. No need for a gasket. No need for a rear hanger either. It is plenty sturdy without a rear hanger.

I went to summit to look around, do I need exhaust clamps or muffler clamps? they appear to be different

i believe that it is a muffler clamp..http://store.summitracing.com/partdetail.asp?autofilter=1&part=SUM%2DG4725&N=700+115&autoview=sku

long_tall_texan · **Posted:** Mon May 04, 2009 12:52 am

Yes. It is a muffler clamp like in the previous post. But they are a lot less expensive at the local parts store. Only about 4 bucks at Oreilly's. And yes, I did remove the rest of the tail pipe that goes to the back of the Jeep. I just put a turn down pipe right after the muffler.

0311_DoC · **Posted:** Sat May 30, 2009 10:48 pm

So is this where you are saying to cut the slit in the pipe?

tjkj2002 · **Posted:** Sat May 30, 2009 10:52 pm

0311_DoC wrote:

So is this where you are saying to cut the slit in the pipe?

You can cut there,I didn't and it's not really needed.That muffler is pretty tiny isn't it?

0311_DoC · **Posted:** Sat May 30, 2009 10:59 pm

yea I like that its tiny. and I noticed the intermediate pipe fit right into the muffler, its not a snug fit. but does fit. so I guess I just clamp those two and clamp the other end with the turn down right? and should be good to go?

tjkj2002 · **Posted:** Sat May 30, 2009 11:01 pm

0311_DoC wrote:

yea I like that its tiny. and I noticed the intermediate pipe fit right into the muffler, its not a snug fit. but does fit. so I guess I just clamp those two and clamp the other end with the turn down right? and should be good to go?

Yep

0311_DoC · **Posted:** Mon Jun 01, 2009 6:24 pm

well i did the install today pretty much looks the same as TJKJ's does. my concern is the lack of a hanger. there seems to be a lot of play or wiggle room if you to hit a bump or something and all the weight is on the intermediate pipe that connects to the cat.

VoodooMann · **Posted:** Mon Jun 01, 2009 6:33 pm

odd, I really have to crank on mine to make it move at all.

I mean solid as a rock, even when i tighten it up with my huge 1/2" ratchet i don't even need to hold onto it

0311_DoC · **Posted:** Mon Jun 01, 2009 6:40 pm

well the anchor point is at the cat obviously and then the muffler as little as it is and the turn down, but i can push the whole assembly up at least a good 2 inches, so like i said if i were to hit a bump its gonna bounce and put stress on the anchor point at the cat and start of muffler... so in essence the muffler duz hang down a tad ill take some pics and post

0311_DoC · **Posted:** Mon Jun 01, 2009 6:52 pm

ok here's the front near the cat

the rear of the muffler and turn down

this me pushing it yo towards the body its a almost a good 2 inches of play from where it hangs to

here's where it just hangs.. i know its not great detail

VoodooMann · **Posted:** Mon Jun 01, 2009 9:17 pm

wow, I can't make mine move up more than 1/4" max

oddball · **Posted:** Mon Jun 01, 2009 10:59 pm

long_tall_texan wrote:

Nope. I did not weld at all. TJKJ did, but I wanted to be able to re-use the intermediate pipe for other possible muffler options down the road. Yes, there is a ever so slight exhaust leak where I cut the slits in the in and out tubes. But not a problem. Passed inspection with no problems.

I still don't understand the need to cut slits?

tan's2002kjlimited; Tom do you need a flange? I can get Dynomax 51002 cheap. Like $17.46 including tax. And as for clamps, they're $2.68 (for 2 including tax) through my parts guy.

lil black liberty · **Posted:** Tue Jun 02, 2009 1:19 am

Robbrez wrote:

0311_DoC wrote:

long_tall_texan wrote:

Nope. I did not weld at all. TJKJ did, but I wanted to be able to re-use the intermediate pipe for other possible muffler options down the road. Yes, there is a ever so slight exhaust leak where I cut the slits in the in and out tubes. But not a problem. Passed inspection with no problems.

so when u all did this to your exhaust you just left the muffler near the cat but did not use the pipes all the way to the rear of KJ right? just a tip directly off the muffler?

when i buy mine this week hopefully i am not going to dump it right down ...i dont like the idea of all the fumes under the car sitting at a light or something
im going to get some more pipe to fill the gap after the muffler because the flowmaster is about 13 inches shorter i believe and just clamp it together to the preexisting pipe

but it seems that a lot of folks just dump it right down after the muffler ..i personally dont like the idea

I'm just going to throw my 2 cents in here.. Mine is dual dumped down right before the back axle, I have no problems with fumes because they spread out faster, when it's cold outside it's pretty sweet to see though because it looks like the Liberty is in a sauna with all that exhaust around it

I have never had a problem with my exhaust at a stop light/stop sign/highway/dirt road/ rock road/ nothing.... I did have one problem however the guy who put mine on didn't do as I asked, I originally wanted it straight piped out the back but he said blah blah blah I ain't got the machine to make bends blah blah blah and I was like well do whatever it takes but I want it to sound sweet, and it does.. I've got a youtube video if you'd like to hear it..

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