Replace the Exhaust on a Jeep Wrangler
You can replace the exhaust system on the Jeep Wrangler in pieces or completely from the engine to the rear of the Jeep. The system uses a header pipe, a catalytic converter, and a muffler and tailpipe assembly. In most cases the muffler and tailpipe assembly is the only section you will replace, unless you are adding a performance system. The entire system bolts together and hangs onto a few rubber hangers for ease of replacement.
1. Jack up the Jeep and support all four corners by placing jack stands under the frame rails. Get the Jeep high enough to work comfortably under it while still allowing you to reach all the bolts.
2. Remove the two rubber hangers that hold the tailpipe assembly behind the axle. They will just pull off the mounts on the frame with a little effort.
3. Locate the flange where the muffler and tailpipe assembly joins the catalytic converter. Remove the two bolts, using a wrench or socket and ratchet, and separate the flange. Slide the muffler and tailpipe out from under the Jeep.
4. Locate the flange at the front of the catalytic converter, and remove the three bolts in that flange using a wrench or socket and ratchet. Remove the converter from the Jeep by sliding it out of the rubber hanger to the left side of the converter.
5. Locate the four studs on the base of the exhaust manifold where the head pipe attaches. Remove the four nuts using a deep socket and ratchet.
6. Remove the head pipe by lowering it down from the Jeep. Install the new head pipe by sliding it up into position and installing the four nuts onto the studs. Do not tighten them completely yet.
7. Install the new catalytic converter by first sliding the mounting rod into the rubber mount under the Jeep. Align the mounting flange with the one on the head pipe, and loosely install the three mounting bolts.
8. Slide the new muffler and tailpipe assembly into position under the Jeep, and slide the two mounting rods into the rubber mounts on the frame rail. Align the mounting flange with the flange at the back of the catalytic converter, and install the two bolts that connect them.
9. Start at the head pipe and tighten the bolts, working your way toward the back of the Jeep until all the bolts are tight. Check each location where the pipes join to be sure there are no exhaust leaks.