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Old July 30th, 2013, 09:37 PM   #1
TC97TJ
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Question Exhaust Help...

Exhaust is bad on my '01 TJ 2.5L so I picked up a basic (AP I think) replacement muffler and tailpipe at local parts supplier.

Q: How do I get the existing muffler away from the cat? I can drop the belly pan to reach just fine, but there are no heads or nuts on the bolts to get ahold of... am I missing something? The new muffler came with the same style bolts already in the flange so I want to be sure not to damage the cat or the flange... I can take a sawzall to the muffler-side pipe but I would still have to seperate the flange.

Any help would be appreciated!
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Old July 31st, 2013, 10:53 PM   #2
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If its the stock setup you cant without a sawzall or pipecutter. and if you go that route cut closer to the existing muffler.....if it is clamped a air hammer with the proper exhaust attatchments works well...otherwise enjoy prying and hammering...clamped ppe is a real pain in the ass. this info is based off my 97 with a 2.5...should be the same.
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Old August 1st, 2013, 12:33 PM   #3
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i think he is working on a 00 or newer that uses a 2 bolt flange, the studs are pressed in from the back side pointing forward, the nuts are probably just rusted beyond recognition, use a cut off tool and cut off the nuts, then pry it apart, air hammer with chisel works great between the 2 flanges, then get new nuts for the studs on your new muffler
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Old August 3rd, 2013, 06:19 PM   #4
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Quote:
Originally Posted by sandfox4 View Post
i think he is working on a 00 or newer that uses a 2 bolt flange, the studs are pressed in from the back side pointing forward, the nuts are probably just rusted beyond recognition, use a cut off tool and cut off the nuts, then pry it apart, air hammer with chisel works great between the 2 flanges, then get new nuts for the studs on your new muffler
Thanks.
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Old August 3rd, 2013, 06:33 PM   #5
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I used an angle grinder to cut a slit in either side of the muffler attachment and then parted the new halfs with a flat head and pulled it out.
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