0ur buddy Jeff's Grand Cherokee WJ has 250,000 miles on the ticker and still has the stock catalytic converters, muffler, and tailpipe. He asked us if we would mind putting some new exhaust parts on the rig since the existing parts had high mileage and some dings and dents from off-roading. He said he felt like one of the cats was backed up, which can happen, especially on a 4x4 used off-road, because the honeycomb-like center of the cat can break loose and get turned in the housing.
We enjoy doing exhaust work and have done enough to know a trick or two to make the job go a bit easier. For this job we installed a new aftermarket downstream cat and a Flowmaster muffler and tailpipe. Here is what we did and some tips to help you along the way with any 4x4's exhaust revival and upgrade.
1 This Jeep, like many from this time period, has pre-cats and a post-cat. The pre-cats looked pretty good from the outside, but the post-cat and muffler looked like they had met more than a few rocks or other trail obstacles while off-road. We told Jeff that he might want to replace the Y-pipe with the pre-cats, too, but first, we would check the cats for damage.
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