Topic: another exhaust quest.

[dexetr30]

Anyone happen to know what size the exhaust pipe is on a stock 02 tj? I'd measure mine but he wife has it again at work today. I have an new dynomax muffler :twisted:  sitting around the garage that I was thinking of maybe swapping the stock one out for.

[dexetr30]

Ok, the wife came home so I'll answer the question myself. Using a set of calipers I got a measurement of 2 & 5/16 inches O.D. So... the Dynomax muffler will fit!

So this is what it feels like to do Lenos monologue.

[Jesse-James]

Let us know how you like it after you get it installed.

[Jeffy]

Ok, the wife came home so I'll answer the question myself. Using a set of calipers I got a measurement of 2 & 5/16 inches O.D. So... the Dynomax muffler will fit!

So this is what it feels like to do Lenos monologue.

Just a FYI, exhausts are measured in ID not OD.  2.25" and 2.5" are common sizes.  In anycase, with the flare it will be larger then the stock pipe.

[dexetr30]

Jesse-James, Ill' post as soon as it's on. I won't get a chance to put it on until this coming Sunday.

Jeffy, I wasn't able to get an i.d. measurement because of the angled cut on the tailpipe. I took the o.d. measurement just to get a close idea. So I'll just assume the i.d. is 2.25. I may need to sleeve it to make it fit since the muffler going on is 2.25 also.

I need to get a small wire feed welder for these types of things. :(  Maybe the wife will get me one for x-mas.

[Jeffy]

Jesse-James, Ill' post as soon as it's on. I won't get a chance to put it on until this coming Sunday.

Jeffy, I wasn't able to get an i.d. measurement because of the angled cut on the tailpipe. I took the o.d. measurement just to get a close idea. So I'll just assume the i.d. is 2.25. I may need to sleeve it to make it fit since the muffler going on is 2.25 also.

I need to get a small wire feed welder for these types of things. :(  Maybe the wife will get me one for x-mas.

That's the reason why I like bolt-on.  No need for a welder.  As long as the muffler slips onto the pipe you can fill the gap with weld.

[SMC4WD]

That's the reason why I like bolt-on.  No need for a welder.  As long as the muffler slips onto the pipe you can fill the gap with weld.

I need to buy a new cat and I thought the same thing...   but then I thought, slip on and weld, or weld...  either way you gotta weld.  Bolt on requires welding on flanges...  still weld or no weld?  It ends up needed welding either way.

[dexetr30]

Here's my method (as incorrect as it may be): Cut the flanges off permanenly, slip on the new muffler or cat and then use stainless exhaust clamps to seal the deal. It looks a bit messy but does the job. :wink:

[Jeffy]

I need to buy a new cat and I thought the same thing...   but then I thought, slip on and weld, or weld...  either way you gotta weld.  Bolt on requires welding on flanges...  still weld or no weld?  It ends up needed welding either way.

If it's truly 'bolt-on' the cat will have a flange on it and the muffler will have flared ends and clamps.

[Jeffy]

Here's my method (as incorrect as it may be): Cut the flanges off permanenly, slip on the new muffler or cat and then use stainless exhaust clamps to seal the deal. It looks a bit messy but does the job. :wink:

The TJ is a bit different then the YJ depending on the year.  I believe the earlier TJ's had the cat connected to the crossover pipe.  Later on they went back with the bolt on cat.  Weird thing is not all cats are ODBII certified.  Most if not all aren't.