exhaust work

[FarmerBrown5]

Hey guys, I am putting on my new muffler and tailpipe today and when putting everything together I have found that the CAT has a small dimple on the bottom and only allows an inch of the muffle inlet to be slid on. The outlet end of the muffler going over the tailpipe is about the same, maybe a tick more to work with. If it were your truck, would you clamp it down with that little to work with, or do something different? I could buy a new CAT with a longer outlet, but this CAT seems to be fine. 

 

[ComancheKid45]

[FarmerBrown5]

Not too fond of welding on exhaust....It is much cleaner looking, but if something changes down the road I do not wanna be forced into cutting anything up. plus I am using a 150$ muffler that I do not wanna chop haha.I plan to use muffler and tailpipe sealer to prevent exhaust leaks. I just didn't know if an inch on both ends would be enough to feel comfortable with. 

[Keyav8r]

Use a heavy c-clamp to flatten the dimple out and get at least 2" engagement on both ends. 3" would be better. With only 1" engagement you'll be flexing the joint every time you run over a pavement joint (or pot hole). If you can't get more engagement, weld it.

[DirtyComanche]

Take the dimple out, above idea using a C-clamp is probably a good way, or a hammer and dolly if you're the type, or get a tailpipe expander and open up the other side so it can go in more.

 

1" ain't enough unless you're welding it.

[fiatslug87]

You can use exhaust band clamps, available at Summit/Jegs/local parts stores. They come in preformed for overlap or lap for butt joints.

 

[FarmerBrown5]

The band clamps crossed my mind, but I wasn't sure if they would hold off that well. Help a friend delete his muffler and he bought some of those clamps and we could not get the clamps tight enough to keep the tailpipe from rolling around inside the clamp. Ill have the jeep on the lift again today for an oil change and an oil filter adapter o-ring change, so while there I will see what I can come up with. I will need to add pipe if I do not weld where it is at now.  If I pull everything in to get more pipe to clamp onto my tailpipe will then be touching the rear shackle.

[FarmerBrown5]

Put the Jeep back up on the lift to find that the two bolts that go through the bracket that is in the crossmember had broke. One had been gone for some time and the other looked to be holding on by very little. Basically the exhaust is not supported in that section well anymore. The bolts into that flange are rusted away so no unscrewing them which is why I was hoping an inch of pipe to clamp to would be enough in the first place and also happy that the CAT seemed to be functioning properly. I can try and cut the bolts out where the gasket is in between the two and then prey I can punch or drill out the bolts. I have a cherokee that has the down pipe and a newer CAT on it. It is a 93 and it looks like it would work, but if I am not mistaken the down pipe is larger in diameter than the one on my comanche. If I were able to swap that in It would make future exhaust work easier (I hope this is the last exhaust job on this truck). Any idears?

[DirtyComanche]

This is a Renix or a HO? The Renix and HO use a different downpipe, different collector flange and gasket, and it should be a different flange at the tranny crossmember, so it is not interchangeable.

[FarmerBrown5]

1992 Eliminator. This truck has the 4 bolt flange on the downpipe and the CAT. my 88 Eliminator RENIX is the same flange style. 

[DirtyComanche]

Yup, well then it should be fine.

[mjeff87]

FYI, you can buy a replacement flange kit for that crossmember flange.  They're hard to find, but I've used them in the past.  Lemme see if I can find a part #....

 

Jeff

 

edit:  It's a Maremont #30175 kit, but nevermind....I see your problem is at the other end of the cat.

[FarmerBrown5]

Indeed it is. If the 93 downpipe clears and will work then I can happily be rid of that 4 bolt flange. It will also save me from spending more $$$ 

[gogmorgo]

Can't guarantee it's identical between Renix and HO, but my '91 had the four-bolt flange originally, and the '93's downpipe fit perfectly. I picked one up specifically because it didn't have the flange.

[FarmerBrown5]

I put mine on yesterday and it fit just like the old one. Very happy to get rid of that flange. I had a hunch it would work since there was only a year difference between the two vehicles. Definitely something I will remember. Hopefully getting my muffler back on this afternoon then relaxing  :cheers: