Topic: 97 TJ 2.5L Exhaust replacement

[david97tj]

Hello guys,

I am new to this forum. I noticed there were alot of 4 Bangers on here. So I thought I would ask a question. I am about to replace my exhaust on my 97 TJ (2.5L engine) with the following...

1. Banks stainless torque tube header
2. Random Technology Hi-flow catalytic converter
3. Banks stainless cat-back (stinger)

My delima is... The OEM cat seems to be welded to the head pipe. There is a hanger/brace upstream from the cat that is welded to the head pipe and connects to the skid plate. I guess I am going to have to cut the cat from the head pipe. If I cut the head pipe where it meets the OEM cat, will there be enough room to clamp an aftermarket cat onto the head pipe? I want to retain the head pipe hanger/brace. Anyone have any experience with this? The rest is pretty much bolt on. Any information would be most appreciated.

Thanks,
David Russ

[Jeffy]

Well, I'd buy the cat first and see.  Is the RT cat bolt-on?  RT is really expensive.  For $100 less you could go with a Carsound Hi-Flow Stainless steel cat.  If you want cheaper then Summit or JEG's sells performance cats in the $50-70 range.  I'm not sure if they're stainless steel though.

If no one sells a bolt-on(clamp on in your case.)  You might have to get a universal model with a long input pipe,  Then have it flared to slip over the downpipe to the Header. The down pipe should come with the Header.  You might want to email Banks and see what they say and what they recommend since you'll be using all new parts.

[david97tj]

Well, I'd buy the cat first and see.  Is the RT cat bolt-on?  RT is really expensive.  For $100 less you could go with a Carsound Hi-Flow Stainless steel cat.  If you want cheaper then Summit or JEG's sells performance cats in the $50-70 range.  I'm not sure if they're stainless steel though.

If no one sells a bolt-on(clamp on in your case.)  You might have to get a universal model with a long input pipe,  Then have it flared to slip over the downpipe to the Header. The down pipe should come with the Header.  You might want to email Banks and see what they say and what they recommend since you'll be using all new parts.

I have already purchased the RT cat.  It is a clamp on.  Although, I am pretty sure I can weld it.  Banks does not make a head pipe for the 97 TJ 2.5L as the head pipe is stainless steel from the factory.  The issue I have is there doesn't seem to be much room between the OEM cat and the head pipe hanger (see image).  I was wondering how I am supposed to deal with it...  Cut the head pipe upstream from the hanger or cut the head pipe at the cat and clamp it there (just doesn't seem to be much room).  I would like to keep the hanger intact.

[Jeffy]

Wow, that pict is huge!  I thought I was looking at the moon for a sec.

You're going to have to look at long long the cat is and mopare it to where the Muffler will sit.  I suspect that you'll loose that hanger though.

[david97tj]

Sorry for the large picture.  I should have reduced it size.  I just attached one I had sitting on my web server.  After looking at the cat, I think that if the head pipe is cut @ the mouth of the cat (where it is currently welded) it will work fine and I won't lose the hanger.  

Sorry for the moon shot!

[david97tj]

I have resized the picture to 35% of it's original height/width.  The bulletin board appears to be stretching it.  It is 157x118 (w/h) pixels.  That is pretty small.  I tried.

Cheers,
David