Installing A Muffler And Tailpipe For A Jeep Wrangler YJ

As well as being part of my less than $880 Jeep project, I’d been putting off installing a new muffler for a couple of years now. Here is the run down for the parts cost of this install:

Tailpipe $20.99
(2) 2 1/4″ Clamps 3.98
Dynomax Super Turbo Muffler 49.99
Shipping 10.00
Total $84.96

New Muffler and Tailpipe
New Muffler and Tailpipe

I wanted a little more room so I jacked up the side of the vehicle the tailpipe and muffler were on.

The nuts on the muffler and tailpipe clamp bolts were a little rusted on. A shot of WD40 and waiting for 5 minutes helped unlock the nuts a little.

WD40 Rusted Bolts and Nuts
WD40 Rusted Bolts and Nuts

Removing the tailpipe clamp near the tip of the tailpipe was pretty easy.

Removing Rear Tailpipe Bracket
Removing Rear Tailpipe Bracket

Remove the clamp on the catalytic converter side of the muffler.

Removing Old Front Clamps
Removing Old Front Clamps

The other end of the tailpipe and muffler were welded together so there were no clamps to remove from there.

The tailpipe support near the muffler took a little more effort. A pair of channel locks allowed me to pinch the support in the middle to maneuver it out of the rubber holding pieces.

Dropping the tailpipe

After disconnecting the hangers and clamps, I used a 4″ angle grinder to cut the old tailpipe from the muffler. Sorry no picture. There were too many sparks flying.

In order to more easily get the new tailpipe in place the passenger’s side of the vehicle was lowered and the driver’s side was raised.

Raising Driver's Side Of Jeep
Raising Driver’s Side Of Jeep

The expanded opening allows for plenty of room to maneuver the new tailpipe in place.

Expanded Opening For New Tailpipe
Expanded Opening For New Tailpipe

The new was put in place and attached to the hanging supports.

New Tailpipe In Place
New Tailpipe In Place

Once the muffler and tailpipe were put in place and positioned the 2 1/4″ clamps were applied.

Clamped New Muffler
Clamped New Muffler

Clamped New Tailpipe
Clamped New Tailpipe

Lastly the tailpipe was attached to the rear hanging bracket.

Attached New Tailpipe To Rear Support
Attached New Tailpipe To Rear Support

17 thoughts on “Installing A Muffler And Tailpipe For A Jeep Wrangler YJ”

  1. How high did you raise the drivers side. I can’t seem to get enough clearance to fit the tailpipe over the sway bar

  2. Thanks for the tip….saved me from taking it to a shop. I did have to jack it up pretty high…even then I had to force the pipe between the rear diff. and the gas tank cover. After that everything went together just fine.

  3. Thanks for the info. Pictures make it so much easier to understand.
    I was at wits end with the tailpipe. I’m going to try your way right now.

  4. how much louder is ur jeep now? ive been thinkin of gettin one of the super turbo mufflers

  5. I think one of your advertisements caused my internet browser to resize, you might want to put that on your blacklist.

  6. i used this method today and it worked for me, had to jack up the drivers side about 24-26″ to get the clearance, but it made it between the rear diff and the gas tank. thanks alot!! MUCH APPRECIATED

  7. The trick is: you feed the tail pipe in from the passener side to the drivers side and clearing the sway bar on that side and then just slide the tail pipe over to the passenger side. The tail pipe will never fit through the opening above the sway bar on the passenger side. If you take the rear wheel on the passenger side off you hav mor room to work, but it’s not necessary.

  8. SUPERB!!!!!..BANGING AROUND IN MY HEAD TRYING TO FIGURE OUT A WAY TO GET THE TAIL PIPE INSTALLED…AS IF i WAS IN A BAR TRYING TO FIGURE OUT ONE OF THOSE METAL TANGLED BAR GAMES!!…WORKED LIKE A CHARM!!…THX!!

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