New exhaust replacement catalytic converters to tailpipe

Would you look on the sticker on the header panel or under the hood and see if it says the Libby has either Federal or California emissions? The converters use one V clamp on each to attach them to the exhaust manifolds. Then the right one will use a flange gasket to attach to the Y pipe. Now at the flange on the Y pipe you attach the undercar converter, this goes in front of the muffler. Then to attach the muffler it depends on which one you have, The OE fit versions from Walker use a donut seal and a direct bolt flange and two spring loaded bolts to hold things together. They also have a version that uses a short adapter pipe that bolts to the flange and then the muffler clamps to that. If that is the style muffler you have and because you want to keep the Libby a while you may want to use band style clamps instead of the common U bolt type. When the pipes rust off the band type are much easier to deal with and they seal better. Behind the muffler you have a clamp as well that holds the tail pipe to the muffler. I attached images of the right cat, two styles of the left one, one is OE style the other is a split version, the split style tends to leak but are easier to install. Then the OE style flanged muffler and the actual Mopar item. If you bought a muffler without the direct bolt flange you will need the adapter pictured next to go into the front of the muffler so it can bolt to the converter. Then the muffler and tailpipe.

Thank you. I will check under the hood and I will also send pics of the parts I have. Yes I just decided to do it the right way with both. Cats and man some of those clamps are pretty pricey but you get what you pay for I guess. Yes my mom had the same year but hers was serviced regularly and it lasted forever it seemed. This engine seems very dependable and strong. The underneath is beautiful as far as solid frame and no rust. The inside is clean. The outer rockers are the only parts I've found that had some rust and I have those coming as well. Thanks for your fast response. It certainly isn't my 1st choice of a vehicle but as long as I have it I might as well fix it all and fix it right. Thanks again.

It's a shame they removed the OE parts, the factory exhaust was much better quality than any of the aftermarket stuff. If it's in good shape other than the rockers I would suggest giving it a real good bath and having it coated with either Krown or Fluid Film. Both will get into the body seams and stop rust. If you can fabricate steel you can make a much better rocker out of large straight exhaust tubing. Also as an upgrade, if it still has the stock capped lug nuts go on amazon and order some McGard tuff nuts to fit it. The OE capped ones are soft and the salt destroys them in a short time. The tuff nuts are solid steel and plated and tend to last.

Thank you for the helpful tips. I got an estimate on my exhaust and it was $1,086.00for parts only not including the y pipe. I have under $500.00 in parts now minus the clamps. I do have someone with a garage and a make shift lift to stand under it and I'm assuming it's going to take a little heat to get the old one off. I've already replaced both valve cover gaskets, MAP sensor The annoying power steering pump and pulley brakes and rotors New battery fixed the snake cables in front doors/ windows. The suspension is in great shape the underbelly is really not bad at all. It was winter and I needed 4wd where I'm at in PA right now so this came along and I settled. One project at a time and now the weather is getting nice. He had put a lift kit on it. The lower half all around including over the wheels is all that textured bed liner which I'm going to redo after the rockers. You mentioned lug nuts Ill have to check. The wheels are all black with 235/75/16s on front and 245/70/ 16s on back. I believe that year and model can put 17s on it. I've been looking at running boards or nerf bars or even individual steps all around. It will look nice in a few months but 1st things 1st..that exhaust! Its quite obvious someone needed a few bucks and took the converters off. I have one pic of the muffler. The rest are still in the wrapping. I'll post them this am. Thank you very much for answering my question. Yes I'll invest in the good clamps instead of the u clamps. I figure that will be another hundred or a hundred and a half if I need that part for the muffler. Oh well It will be done and done right. Thank you for answering my question. This is such a great site!!!
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Being a NYer myself I know what this states roads do to vehicles so I try to help save them.

Thank you. Years ago I had the same mechanic I've kept over the years tell me that after an oil change to get under my vehicle. scrape off any loose paint or rust off then with a paintbrush or sprayer and put that oil up underneath. He said it would condition and keep it from rusting.

Well, I have pics of the new exhaust parts I can leave a few pics for you. A few look upside down. I put in over 70 hours at my job this week so I feel a little upside down. myself haha If you could tell by looking at them if maybe that one part is welded to the muffler already or is that something different? I believe there is a flange on the end of one side of the converters. I just need to figure it all out although you have already told me the clamps and how many I need. So instead of the U bolt clamps do you mean the band sleeve coupler-like clamps? I'm not good with the correct terminology lol I do believe I DID buy all Walker parts. I forgot to look under the hood. I'll check that with a flashlight the next time I take my dog out. Thanks so much...

would this be the correct part I need for the exhaust if it is not on the muffler?

I took a pic of the sticker on the inside under the child not dare if you can see it it's dark but I believe vin says all US and Cali.

Okay, it looks like you still need the middle converter for it to be legal. The muffler you have doesn't need the adapter, it's one of the better ones that is a direct bolt on as it has the front flange. Yep, that is a California version so it has three converters under it. Stupid really as the front two are monitored but the rear is just along for the ride, but that's the Feds for you. The easy way to get the rusted V clamps off is a cut off wheel through the bolt. I would check that the tires are the exact same diameter, the 4 wheel system won't like it if they are different.

Yes, I always thought with 4 wd all of the tires should be the same size. I'm pretty sure I will never use 4 lo. I used part-time a few times to get out of my driveway. I purchased this in February. I will get another set of tires front or back it really doesn't matter to me the tires are all fairly new. A third converter huh? I myself have never come across this on any other vehicle I've owned. I was just looking at the estimate I got from a garage here and the only parts he listed were left and right-side converter, muffler, and tailpipe. He had listed the part numbers next to the parts so It made it easier to find and order them. I only replaced the Y pipe because it would have been the only part that wasn't new under there and it looked pretty weathered to me and I just figured it would be easier to take the old system off and put the new system on if they were all new parts. I've been doing part searches off and on all night and I still haven't found the middle converter. I need to check and see what size clamps I need to get those ordered the sooner they get here the quicker I can get the new exhaust on. So would I need a third 02 sensor also? I have a NY license and plan on getting a NYS inspection. The inspection was good until 10/21 so I wasn't in a hurry. The notary here told me that even though it's a PA inspection NY will honor it until then.. Well, I'm going to try to find and order the clamps and middle converter if I can find it. Thanks for all of your help.

would this be the part? Is it possible that there is a universal one of these or is this going to cost me another few hundred? I might have to put this exhaust up for collateral and take a loan out on it ,LOL.

You might not need it on an 04, I know my 02 had it but it wasn't monitored so no sensors. One parts list shows it but another doesn't and both are OE files for the 04.
The rear unit isn't monitored on them unless it's the 4 cylinder as that is the only unit they have so legally if it isn't used it doesn't really need to be there. I would lay out the parts you have and see how it fits under the jeep. The two front units will have a total of 4 O2 sensors which do all the work.

Okay. I'm getting a bit confused. so far 2 V clamps for cats, a spring and bolt kit for the right side cat 2 coupler band clamps 2.25 one for tailpipe and one for y pipe and do I still need one more band clamp and that gasket ..I hope. I'm trying to order them now. I put a pic of those coupler band clamps I should use instead of the U bolt clamps not sure if I have them right. To me, a clamp is a clamp. yikes

One V clamp and donut gasket for each cat to manifold joint. Then a clamp for the left cat to the Y pipe. Bolt and springs with donut for the right cat to Y pipe. That gets the Y pipe to engine side. Then donut gasket and springs and nuts for the muffler to Y pipe, and a clamp for the muffler to tail pipe. Those are the good clamps. The nice thing with them is they don't crush the pipes and cause issues if you need to take things apart in the future, and you can just snug them up as you put the system together until you get all the pieces into the hangers and position. I normally do the engine side first, then hang the tailpipe and slide the muffler into it with a snug clamp. Then couple the muffler to the front pipes.
Adjust it all to get things into position and start snugging the clamps up, then once it's all in, torque the clamps down good. If there is any doubt that a joint could leak you can apply a bit of the exhaust paste they sell as a sealer.

Oh, okay. I knew I was getting mixed up. Lol. Thank you so much. That was another reason I wanted all new parts. Like you said tighten them all up then I thought about going out running it a bit then torqueing them all down while it's hot. I'm glad it doesn't need welded up. Maybe I can do this myself! I have found that if I do things myself I feel a sense of pride and accomplishment. I'm getting excited to get this done! Again thank you so much for being patient and taking the time to answer all of my questions. You really have taken a lot of time finding diagrams explaining things and even giving step by step instructions. I hope you have a great day today!

Hi,

I noticed we haven't heard from you for a couple of days. Have you made progress with the exhaust system? If possible, let us know. We are interested in knowing.

Take care,

Joe

Hi, I have been waiting for the clamps, gaskets and spring and bolt kits to be delivered. They want almost $39.00 for a V clamp here at local parts stores so I stopped around online. Tracking is showing Friday the 7th and one V clamp kit the 8th. It will most likely get to a next Monday or Tuesday. Thanks for checking though. While I'm waiting I had to start another thread/question for intermediate steering shaft. That's the little tug I had been feeling. I have been comparing prices online for that. i have found those from almost $400 to around a hundred. After this "fixing all the small things" this thing better last a few years, lol.

Hi,

If you have a chance, let us know when the parts get there and how things turn out for you. As far as the steering, I will look for the other thread.

Take care,

Joe

Thank you. I was surprised the donut gaskets band clamps and spring and bolt kits arrived today. I'm just waiting on the V clamp kits. I will definitely let you know. Maybe I can get that done this weekend. I have a reciprocating saw and an angle grinder a set of steel ramps and some blocks of wood. I would love it if I could just do it myself here and not even ask for help. Have a great night.

Feel free to let me know if you run into trouble. You can do it at home. Just make sure it is properly supported. Never trust a jack alone.

If you try it and run into trouble, I'll try my best to help.

You have a great night as well.

Joe

I do not trust Jack's alone. I have a few jack stands I can use of my neighbors and some big blocks of wood. A good friend of mine was underneath his travel trailer levelling it out about 5 miles out of town around 5 years ago. The trailer fell on his chest and by the time the ambulance got there it was too late he was only 50 years old. The sad thing is he wouldn't have let anyone else do what he did. Thanks for the reminder though. Often people think it can't happen to them until it does. Maybe I will go to my friends garage. The job will go faster with another set of hands.Have a great night!

That sounds like a good plan. Just be safe.

Take care,

Joe

Thanks. Just as an example; the V band flange clamp kit is $49.99 apiece at the local Auto parts store ( I won't name names) out of curiosity I looked at it to see if it was the same material etc as the ones I got for $7.99/ea and it was. I know parts stores have to make a little money but then normally a mechanic makes a few bucks off the parts and there's nothing wrong with that. I'm just happy that my friends dad is a mechanic and he has offered to do the job. Of course I'll pay him. Probably with the money I saved on parts, lol. I will post pics when it's done. Thanks so much.

Okay, I have not started this yet. The weather has not been the greatest rain rain and more rain. We actually have a freeze warning tonight too. I was looking at the diagrams maybe I'm looking at are wrong one but I noticed one had a T Bolt Clamp. Do I need this clamp also. I do not want to start this and I need something. Maybe that was the split converter you said one of the diagrams were. I have Friday off and weather permitting if I do not hear back from my friend I'm going to jump in and just try this myself. Thanks

The T bolts are on the V clamps. The clamps wrap around the two flanges with the donut in the middle and use a bolt to tighten down. The OE ones use a T bolt, aftermarket ones use T bolts or have welded on bolts. Both work.
No rush, been raining daily here as well, I'm thinking of buying a hovercraft to mow the lawn. LOL

Right! Well, you can ride your hovercraft out to the houseboat In building, lol. I was hoping that exhaust would have been done before my doctors appointment in NY on Wednesday but it's all good! I have an extra V clamp here if I need something I'll use my imagination, lol. Thanks

Hi,

First and most importantly, I hope everything went well for you in NY. As far as the exhaust, I know it may be some time since you get to it, but please feel free to let me know if you have questions, need help, or just to let me know how things turn out for you.

Take care,

Joe

Thanks and I definitely will. I need to get all those parts out of my entryway anyways so I'm thinking of possibly doing it myself soon. I have an 02 sensor removal tool I have the sensors cuz that one is welded to flex pipe. I have all the clamps and all brand new parts even if it takes me half a day it can't be that hard. I know I can do it I remember changing a muffler on a Renault Alliance I had back in the day! Thanks for being patient with me!!! NY trip went good! Next trip I hope I have an inspection and emissions appointment.

Hi,

I'm glad to hear everything went well. I'm sure you're happy to be home. LOL

I don't know if you need them, but I attached directions below for different parts of the exhaust system. I hope they help.

Take care and let me know if you have other questions.

Joe

See pics below.

Hello, well the hard part is over I think! What a mess. Plus jack stands and blocks of wood really can't take the place of a lift and air tools. 4 hours non-stop and tomorrow the new will go on... I just wanted to show you the mess I was working with. I'm assuming that was the hard part. I hope it was, lol.

Hi,

It doesn't look like it was in very good condition. LOL. That is the worst part because of the rusted parts and bolts. The new parts will be much easier to install.

Take your time and be careful when you're under the vehicle. Please make sure it is safely lifted.

Take care and let me know the outcome.

Joe

Looks typical of a NY exhaust system after a few years.

Thank you. Yes, I jacked it up and put pieces of wood under the front tires and jack stands on both sides underneath and then I let the jack down. You can never be too careful. Yeah I knew it was a mess. I was able to save the upstream O2 sensors. The other two welded to the pipes are getting tossed with the pipe.The guy I bought it from buys and flips cars. There's still a right way to do wrong. I know they sell different size flex pipe so i don't know why he even put it on because even with the clamps he had on there was about 1/2 in gap so it wasn't sealed anyways. Oh yeah I knew it was a mess that's why I dreaded starting it. The original V clamps were still on there. My reciprocating saw sure helped, lol.Thank you as always and I'll post more tomorrow afternoon. Have a good night!

Oh boy. So I ordered one smaller butt clamp. I can't remember which part but it's behind the catalytic converters and y oioe but the clamp just won't tighten down any further. The pipe isn't going out it's in there but the clamp just slides around a bit do instead if a 2.25 in I have a 2.0 coming.I'm going back up to my friends garage even though I'm doing it outside of the garage. There's more light outside. I'm going to have her help me hang it. It just seems there's no room under there at all now. I'm wondering if those old parts were even the right year or vehicle. This exhaust takes up every inch of length under there..I tried to hang the back before I left last night but I was tired hungry and a little frustrated over my tire going flat. Tried putting air in it the valve stem is bad so Im going to have to take it off and take it to the repair place. I worked a midnight to noon ran up there until I had to go back to work from 6pm to 9pm ran up and it was just too dark to see how in the heck I can hang the back. It's been a learning experience for sure but it looks so nice. I'll post pics when I get up there after noon I'm still at my midnight to noon shift. Maybe so shouldn't have tightened everything up so well before I tried hanging it. Thanks again..

Okay, got to untighten a few things. That's why you just put it together loosely then hang it then go back and tighten it. I know nothing about pounds of pressure for torque so I'm just going to pray I get it all right.

Done. Except for the one smaller diameter clamp I got under there and couldn't see or feel any leaks except drivers converter to y pipe..That new pipe smell though. I'll drive it fir swhile then get under there in a werk see if I csn tighten it down. It's very pretty and shiny under there. I will post pics in a few hrs omw to work.

They aren't the greatest, but here they are:

Hi,

It looks great! Good job. As far as the smell, there are stickers and oil on several of the components to identify part numbers and prevent rust. That smell should go away.

Now for the clamp, I'm not sure how you got a 2" one on in place of a 2.25". Usually, they won't fit around the pipe. As far as tightening, just make sure nothing can move. Torque is done using a special tool called a torque wrench. Most people don't own one.

Let me know if there is anything I can do to help. Otherwise, great job.

Take care of yourself.

Joe

I'm not sure I can get that 2.0 clamp on when it gets here either. The 2.25 band clamp aka butt clamp aka coupler clamp just seems big and it's sliding around. The pipes are together real good but when I started the vehicle and crawled back under it that was the only place I could feel air coming out of and I'm pretty sure it was a 2 25 like the other. It just will not tighten down enough so it doesn't move around. Maybe the manufacturer sent the wrong size? I'm not sure I have a 2.0 coming maybe I should have ordered a different 2.25. Thanks. It was not as hard as it seemed. Your written step by step instructions worked better than anything. The pics helped with the placement of the exhaust gaskets/donuts. Thank you so much I could not have done it without your guidance. Thanks again have a great night. I have a few more projects I'll start new threads. Take care.