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New exhaust for '92 Wrangler, questions

776 views 9 replies 6 participants last post by  jamgood96  
#1 ·
New exhaust for \'92 Wrangler, questions

The rattle of the old Catalytic Converter is finally getting bad enough that it's downright embarassing. So I've decided to replace it with a new one. I called the local Master Muffler shop and they quoted me $260 for the install of a replacement Walker unit. I told the guy that Quadratec sold them for jsut under $100. He was kind of shocked, didn't know what to say, you get the picture. Anyway, I asked him how much extra it would be to replace the extire system from the manifold back, he said around $600. I told him no way. I can get an entire Walker system from Quadratec for less than $200 and do it myself.

So now I am going to do it myself. I crawled under there last night and looked at everything. Seems pretty easy I guess. Only one problem. Transfer Case Skid Plate. I am afraid that when I take the old exhaust out, I will have a hard time putting the new one in since it is all above the skid plate. Obviously I can cut out the old system, but I don't think I will be able to access the joint between the Catalytic Converter and the front of the muffler. Is there an easy way to solve my dilemna? Is it really that hard, or am I just talking myself into thinking it is?
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OH yeah, it's the 2.5L exhaust if that makes much difference.
 
#4 ·
Re: New exhaust for \'92 Wrangler, questions

I just finished building my own exhaust from 2.5" pipe. I had the same dilemma, only I found out after I tack welded the center pipe to the down pipe. I thought that I had enough room to get the downpipe/center pipe section off again to fully weld it.... WRONG... Just not enough room no matter how I twisted the pipe, the darn thing wouldn't come out.

What I did was; Supported the skidplate/transfercase combo with a jack, took all the skid plate bolts out and lowered the combo enough to wriggle the downpipe/center section out.

I don't know what the setup is on a Wrangler but lowering the skidplate/transfercase combo might just give you enough room to fit the exhaust...
 
#5 ·
Re: New exhaust for \'92 Wrangler, questions

If you do end up just lowering the skid plate down do yourself a favor and make sure you have plenty of room between the fan and rad. also make sure the fan won't break the shroud. If you have the plastic valve cover be careful you don't break it against the firewall too.

I learned all this from someone else's mistake at a place I worked (not all on the same vehicle tho). Funny how Bosses don't find it amusing having to buy radiators, shrouds or valve covers
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#6 ·
Re: New exhaust for \'92 Wrangler, questions

i guess its possible but why? removing the skid plate takes about 5 minutes to do and will give you all the elbow room you could ever want.

also beware of cat-backs. its been my experience that they are never truly bolt on. there are almost always hanger or adapter mods necessary. if you don't have fabrication or welding experience your gonna have a tough time.

my suggestion is if you don't have the experience buy the kit and/or the cat and take it somewhere to be installed. that way you won't pay the marked up parts costs just labor. shop rates are usually around $40/hour and any good shop can have the cat back installed in an hour or two. i personally hate exhaust work so $40 is worth the aggrevation of doing it yourself.
 
#7 ·
Re: New exhaust for \'92 Wrangler, questions

Support the trans/transfercase assembly with a jack so that it dosen't come down any then remove only the skid plate. that way all assemblys are at the correct position to align the exhaust properly. the only hard part will be removing the old exhaust.
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#8 ·
Re: New exhaust for \'92 Wrangler, questions

In reply to:

shop rates are usually around $40/hour

[/ QUOTE ]

Your lucky then, around here it's $50-60 up around the Twin Cities I've heard of $70+. Lawnmower shops around here are even charging more then $40.

I'm glad I can do most of my own work or I'd go back to a horse & buggy!!
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#9 ·
Re: New exhaust for \'92 Wrangler, questions

ok, so maybe I'm just a little lazy from the way it sounds from you guys. I've had to remove the skid plate before when I had to put in a new clutch, and it was a PITA. But then again, if you have all the right tools, you might as well open a shop.
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#10 ·
Re: New exhaust for \'92 Wrangler, questions

I got a complete custom job done from basically the manifold back for around $250 or so. I bought the cat and muffler from Q-tec, and then paid about $150 to have Meineke bend up some tubing.

I would seriously suggest taking your skid off, it'll make it MUCH easier! It's really not that hard either.