I took the TJ
to Novato Muffler & Brake for thier opinion on how best to install
a muffler/exhaust that would clear the new suspension and retain
the stock exhaust's quietness. They recommended a MagnaFlow muffler
and new tailpipe from the catalytic converter back. I was hoping
not to spend more than the cost of a new muffler, but knew after
looking close under the TJ that there was no way to avoid a new
The new muffler
body is 4" x 9", with 2.25" inlet and outlets to
match the stock tubing. It has a centered inlet and offset outlet.
This was small enough to work with. They told me it would be barely
louder than stock but should provide a bit more horsepower to turn
those 35's. Sounded good to me.
I had them weld
a flange to the exit of the cat converter so that I can remove the
entire exhaust for future modifications or repairs. Behind the flange
is a new piece of tubing that was bent to space the new muffler
down and away from the heatshield and new control arms.
muffler was welded to the short pipe described above, then a custom
tailpipe was carefully measured and bent to go over the rear axle
and around the spring as the stock one does. Instead of exiting
beside the gas tank, where the stocker did, I had them bend it to
exit between the rear tire and rear bumper, so it won't get smashed
on rocks and ledges as it has in the past. (Great idea Steve &
The result was
excellent...the clearance was plentiful, the sound was barely louder
than stock, and the new tailpipe exit does not interfere with the
rear tire. I'm super happy with what I got for about $200.