Morten's Jeep XJ page: Rusty's Exhaust System

Rusty's Exhaust System

My old exhaust system was getting old and rusty, so I thought it was time for an upgrade. First I went to a local dealer, but they had to make a custom pipe for me which would cost too much. Rusty's Offroad had an exhaust system for about one fourth of the price, and it was designed to fit my XJ.

Rusty's Exhaust system included the following items:

Dynomax Ultra Flo muffler
Pipe to go between the muffler and the catalytic converter
Tailpipe with chrome tip
Clamps

The first thing we did was, ofcourse, to remove the old stuff. The clamps were so rusted that they actually just broke off when we tried to unscrew them. Rusty's kit included new clamps, so that wasn't actually much of a problem.

Old and new clamps

Old and new muffler and tailpipe

Our first problem was that the pipe which was supposed to go between the muffler and cat was too short and it didn't fit. So we made a temporary solution until I could get it properly done. On the picture below you see the difference between our temporary solution and the pipe Svendsen Eksos (a local shop) made for me.

Temporary solution
on top

The last problem we encountered was the clamp holding the tailpipe. It would sometimes rub against the leaf spring and make quite a horrible noise. The solution, however, was simple, just rotate the clamp.

Tailpipe

Tailpipe clamp

After all this is done, just start up the engine and listen to the new sound :)
I was a bit worried the new sound would be too "red-neck", but I was positively surprised. The Dynomax muffler makes a deep rumbling sound, which I think suits the XJ quite nicely :)

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Rusty's Exhaust System

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