Hey man you've literally saved me a few thousand bucks over the past few weeks, much obliged! Did you notice a smell similar to electrical burning after install, i know some odor is normal but mine was pretty damn pungent going down the road today. Ill check the sensor wires but i was pretty careful securing them.
So glad to hear that this video helped you out, Ryan! I don't recall an electrical/ozone type smell but I do remember that there were smells. Since I painted everything, I think it was the paint baking off, plus maybe some PB Blaster type of stuff burning off. You might check your O2 sensor wires, especially the upstream sensor because that wire can easily go up against the exhaust manifold or down pipe. I zip tied my upstream sensor's wire out of the way. If any sensor wire actually burns through, I'd think you'd get a check engine light. If the smells don't go away after a couple of days, probably something to look into more. Sorry I don't have a definitive answer.
No problem at all! I confirmed sensor wores are in tact, i think it may have been chemical residue from the factory. It still smells, but not nearly as bad, and it's running the best it's ever run. I can actually hit 60 in 4th again lol
Hi thanks for showing this. I have to replace the muffler and tailpipe and ordered the ones that were supposed to be for the YJ 4.0 1994. But the tailpipe (and probably the cat) do not slide into the muffler. Looks like the muffler inner diameter is about 0.2 mm too small. What do you think is the best option? cutting the pipe and mufler short and use a adapter connector, or try sanding/grinding the outsides of the tail pipe and cat back and perhaps a bit of the inside of the muffler pipes?
I would say it depends on how good you are at that kind of fabrication. I know I’m not good at it so I’d go with an adapter because I can slip it together and clamp it with u-bolts. I think as long as you get the pipes all connected somehow and have them hanging off the ground and not hitting other vehicle parts, you’re good. Sanding/grinding, adapters, straight up welding, etc. Good luck and thanks for watching!
@@CarbonsDIYGarage Actually, just saw a reference to a tool called Exhaust pipe expander, basically something that goes into the pipe and you expand it by turning a wrench or heavy impact: Found some on Amazon in the uk "Exhaust Pipe Expander Tailpipe Expander Tool Set 1-5/8 Inch to 4-1/4". I will let you know if that worked...
Around 15 yrs or so ago, there was a catalytic converter “silent” recall. If it sounded like a bunch of broken glass inside, it is bad. Just an FYI. Mine was replaced by Jeep for free. They were even reimbursing folks who paid to have it replaced.
Nice job as always Ed! I don't have a Catalytic converter on mine. Cats are very pricey. I had heard of the O2 sensor problems before. Didn't know if it was actually a thing or not. Now I know it is. Glad to see you get it done right! Sounds great!
The cat from Wagner wasn't too horrible but it did cost about as much as the rest of the exhaust combined. Fixing the exhaust led to all sorts of new "awareness" from TDSR. Not only did it have to start using O2 sensors again, but it ended up having to relearn how to idle. I've had to replace the MAP sensor and Idle Air Controller but I think she actually sounds close to what she's supposed to now. Thanks, Previous Owner... I don't know if I'm doing it right, but hopefully getting it close. Thanks for the kind words and thanks for watching!
finding the NTK sensors in Germany is almost impossible - for the 23506 I had to ask a friend to bring it from her USA vacation and even that was difficult ($74 btw)...
I have a 2001 tj 2.5 , trying to find the entire kit and am having no luck. Im wondering if the 97-00 kit will fit. Also cant find the down pipe that connects to the manifold. Its driving me insane haha, Any ideas? Thanks
Walker exhaust has a catalog that shows you all the parts, starting with the catalytic converter, and you can order them from Walker, Amazon, RockAuto, etc. www.walkerexhaust.com/find-my-part.html But I also couldn’t find anything about the down pipe, which is crazy. Even the Jeep parts catalog doesn’t have info. Just shows the pipe connected to the cat. (Figure 011-110, page 162) You might consider calling Walker or maybe Summit Racing to see if their customer service folks could help. Sorry! Good luck…
Being honest with you? My thought was that since it was/is a 2.5L, 25 year old, 210,000+ mile Jeep, I would just put it back to a stock configuration because it would be the least expensive, least likely to cause unforeseen problems, and there's not much I can do to make the thing look prettier or run faster. :)
Your video was very helpful! I have a 1998 tj with the 2.5 liter and just replaced the entire exhaust system. Did you have to get extended exhaust flange bolts? If so, what did you buy? I had to replace mine because the stock ones were to short. I have a temporary fix in place now.
Thanks for watching, Charlton and I’m glad it was helpful. By flange bolts, I assume you mean the bolts from the exhaust manifold to the downpipe. No, I used the bolts that came as a part of the manifold (see separate videos on replacing the manifold). I had to line the downpipe up, tilting it “just right,” to get the bolts to extend far enough through the flange on the pipe to get the nuts started. Definitely a pain in the @ss. I know that probably doesn’t help you though. The TJ parts list says the stock studs are .375-16x1.69 (3/8-16 x 1-11/16), part number J4007109
In the process of replacing the entire exhaust on my 00’ TJ with the 2.5. I bought a Crown Automotive kit. I discovered however that the bracket on the down pipe doesn’t fit with the stock bolts from the exhaust manifold… I can’t return the kit because I am past the 90 day limit. Any advise on either adapting it or making it work some other way? Thanks for the help!
Thanks for watching, Redge! If you're doing cat back, leaving the catalytic converter in place, you can certainly do it without removing the skidplate as long as the connection between converter and muffler isn't welded. If you're Jeep's lifted so you have more room to work/see under the Jeep, you can probably do the whole thing without removing the skidplate, though sliding the catalytic converter off its mount on the transmission might be tricky. Frustration may drive you to dropping the skidplate. If you end up having to cut the connection between converter and muffler, you'll probably have to drop the skidplate too. And the O2 sensor will be a bit more challenging to remove with the skidplate installed, unless you just disconnect the sensor harness and take the sensor out with the converter. I hope that helps (and makes sense).
Thanks for watching, Isaac. All totaled it cost me around $525. Half that was the catalytic converter. The rest of the exhaust parts are pretty cheap (you can certainly pay more for a specific look or sound). Definitely shop around. Amazon may not always be cheapest, especially for things like paint , oxygen sensors, clamps, etc.
Check out the video description for extra info, parts, tools, torques, and any updates.
Man, you make it look easy! Hopefully I can do the same.
@@dylweezy117 You got this! Thanks for watching.
If it earned it, please consider giving the video a 👍🏻 and/or sub to the channel.
TJ's are notorious for only taking cheap NTK stuff. Not all sensors, but when they do it's usually best just to use them
It's too bad that it's becoming harder to find some of these NTK/NGK sensors.
@@CarbonsDIYGarage I haven't replaced any sensors in a good while. Good to know. Might buy a CPS b/c I don't recall replacing that one yet
perfect video !
Thanks for watching!
Hey man you've literally saved me a few thousand bucks over the past few weeks, much obliged!
Did you notice a smell similar to electrical burning after install, i know some odor is normal but mine was pretty damn pungent going down the road today. Ill check the sensor wires but i was pretty careful securing them.
So glad to hear that this video helped you out, Ryan!
I don't recall an electrical/ozone type smell but I do remember that there were smells. Since I painted everything, I think it was the paint baking off, plus maybe some PB Blaster type of stuff burning off. You might check your O2 sensor wires, especially the upstream sensor because that wire can easily go up against the exhaust manifold or down pipe. I zip tied my upstream sensor's wire out of the way. If any sensor wire actually burns through, I'd think you'd get a check engine light. If the smells don't go away after a couple of days, probably something to look into more. Sorry I don't have a definitive answer.
No problem at all! I confirmed sensor wores are in tact, i think it may have been chemical residue from the factory. It still smells, but not nearly as bad, and it's running the best it's ever run. I can actually hit 60 in 4th again lol
@@ryanbird5142 That’s awesome! Congrats!
Hi thanks for showing this. I have to replace the muffler and tailpipe and ordered the ones that were supposed to be for the YJ 4.0 1994. But the tailpipe (and probably the cat) do not slide into the muffler. Looks like the muffler inner diameter is about 0.2 mm too small. What do you think is the best option? cutting the pipe and mufler short and use a adapter connector, or try sanding/grinding the outsides of the tail pipe and cat back and perhaps a bit of the inside of the muffler pipes?
I would say it depends on how good you are at that kind of fabrication. I know I’m not good at it so I’d go with an adapter because I can slip it together and clamp it with u-bolts. I think as long as you get the pipes all connected somehow and have them hanging off the ground and not hitting other vehicle parts, you’re good. Sanding/grinding, adapters, straight up welding, etc.
Good luck and thanks for watching!
@@CarbonsDIYGarage Thanks a lot for the reply. I will ponder...
@@CarbonsDIYGarage Actually, just saw a reference to a tool called Exhaust pipe expander, basically something that goes into the pipe and you expand it by turning a wrench or heavy impact: Found some on Amazon in the uk "Exhaust Pipe Expander Tailpipe Expander Tool Set 1-5/8 Inch to 4-1/4". I will let you know if that worked...
@@jwestrik9308 Cool! Yeah, let us know how it goes.
Around 15 yrs or so ago, there was a catalytic converter “silent” recall. If it sounded like a bunch of broken glass inside, it is bad. Just an FYI. Mine was replaced by Jeep for free. They were even reimbursing folks who paid to have it replaced.
Oh wow, that’s good to know! Given the state of my Jeep I think they’d just laugh at me but good tip for others. Thanks for watching and subscribing.
Nice job as always Ed! I don't have a Catalytic converter on mine. Cats are very pricey. I had heard of the O2 sensor problems before. Didn't know if it was actually a thing or not. Now I know it is. Glad to see you get it done right! Sounds great!
The cat from Wagner wasn't too horrible but it did cost about as much as the rest of the exhaust combined.
Fixing the exhaust led to all sorts of new "awareness" from TDSR. Not only did it have to start using O2 sensors again, but it ended up having to relearn how to idle. I've had to replace the MAP sensor and Idle Air Controller but I think she actually sounds close to what she's supposed to now. Thanks, Previous Owner...
I don't know if I'm doing it right, but hopefully getting it close. Thanks for the kind words and thanks for watching!
finding the NTK sensors in Germany is almost impossible - for the 23506 I had to ask a friend to bring it from her USA vacation and even that was difficult ($74 btw)...
I have a 2001 tj 2.5 , trying to find the entire kit and am having no luck. Im wondering if the 97-00 kit will fit. Also cant find the down pipe that connects to the manifold. Its driving me insane haha, Any ideas? Thanks
Walker exhaust has a catalog that shows you all the parts, starting with the catalytic converter, and you can order them from Walker, Amazon, RockAuto, etc. www.walkerexhaust.com/find-my-part.html
But I also couldn’t find anything about the down pipe, which is crazy. Even the Jeep parts catalog doesn’t have info. Just shows the pipe connected to the cat. (Figure 011-110, page 162)
You might consider calling Walker or maybe Summit Racing to see if their customer service folks could help. Sorry! Good luck…
@@CarbonsDIYGarage Yeah I will call them. Thanks so much for going out of your way! It is crazy lol
What do you think about running straight pipes past the catty into duel exhaust
Being honest with you? My thought was that since it was/is a 2.5L, 25 year old, 210,000+ mile Jeep, I would just put it back to a stock configuration because it would be the least expensive, least likely to cause unforeseen problems, and there's not much I can do to make the thing look prettier or run faster. :)
Your video was very helpful! I have a 1998 tj with the 2.5 liter and just replaced the entire exhaust system. Did you have to get extended exhaust flange bolts? If so, what did you buy? I had to replace mine because the stock ones were to short. I have a temporary fix in place now.
Thanks for watching, Charlton and I’m glad it was helpful. By flange bolts, I assume you mean the bolts from the exhaust manifold to the downpipe. No, I used the bolts that came as a part of the manifold (see separate videos on replacing the manifold). I had to line the downpipe up, tilting it “just right,” to get the bolts to extend far enough through the flange on the pipe to get the nuts started. Definitely a pain in the @ss. I know that probably doesn’t help you though.
The TJ parts list says the stock studs are .375-16x1.69 (3/8-16 x 1-11/16), part number J4007109
In the process of replacing the entire exhaust on my 00’ TJ with the 2.5. I bought a Crown Automotive kit. I discovered however that the bracket on the down pipe doesn’t fit with the stock bolts from the exhaust manifold… I can’t return the kit because I am past the 90 day limit. Any advise on either adapting it or making it work some other way? Thanks for the help!
Nice video, There's a way to remove and repair the exhaust without removing the skidplate ?
Thanks for watching, Redge! If you're doing cat back, leaving the catalytic converter in place, you can certainly do it without removing the skidplate as long as the connection between converter and muffler isn't welded. If you're Jeep's lifted so you have more room to work/see under the Jeep, you can probably do the whole thing without removing the skidplate, though sliding the catalytic converter off its mount on the transmission might be tricky. Frustration may drive you to dropping the skidplate.
If you end up having to cut the connection between converter and muffler, you'll probably have to drop the skidplate too.
And the O2 sensor will be a bit more challenging to remove with the skidplate installed, unless you just disconnect the sensor harness and take the sensor out with the converter.
I hope that helps (and makes sense).
How much did all this cost you? Thanks
Thanks for watching, Isaac. All totaled it cost me around $525. Half that was the catalytic converter. The rest of the exhaust parts are pretty cheap (you can certainly pay more for a specific look or sound).
Definitely shop around. Amazon may not always be cheapest, especially for things like paint , oxygen sensors, clamps, etc.