What Else To Do While Replacing Cat Back Exhaust?

PhillyJake

TJ Enthusiast
Joined
Sep 22, 2020
Messages
106
Location
Philadelphia
Hey Yous Guys -

I might be wrong, but I think my '04 Rubicon came with a dual exhaust...



Anywho, not a huge fan of it, so I picked up a new Flowmaster cat-back package. Really looking forward to bolting it on, but figured that while the old one is out and before the new one goes in, it might be an opportunity to do some other fun irresponsible stuff. For example, now that it's getting colder on these Northeast nights, rubber bits and gaskets appear to be contracting and the old girl has moved beyond leaking oil to hemorrhaging oil (this Rorschach is after about a week of sitting - surprisingly, oil level looks ok):
IMG_2981.jpg
So maybe I replace the oil pan gasket? Maybe I crank down on the valve cover? Definitely replacing the OPSU (my oil pressure gauge is flopping around). But what else? I'm open to suggestions and ideas, assuming a moderate level of mechanical competence and a healthy willingness to break things.

Thanks in advance!
 
I'd diagnose exactly where the oil is leaking from before throwing parts at it. Definitely check the rear main seal area and rear of the valve cover. Those are two common culprits.
 
  • Like
Reactions: PhillyJake
The bolts on my exhaust heat shield...I need to put bigger fender washers on to hold up the heat shield. Would be good to check and fix if the exhaust was off.
 
  • Like
Reactions: PhillyJake
I'll have to get underneath and check out where the oil is coming from - the leak seems to be sporadic, so no regular drip, but sometimes nothing, sometimes lots of things. I was able to get in there and replace the OPSU, and didn't see a lot of oil in the vicinity.

FWIW, for anyone replacing their OPSU - GET THE DEEP SOCKET. Just do it. It's not worth the struggle, trust me.

and thanks, @Vtx531, I'll definitely pay attention to those bolts and see if they need attention.

For those that have done the exhaust swap before, I know the components that aren't welded are held together with hose clamps, but is there anything else that I need to put on the joints to create a tight seal? Like PVC glue for plumbing, but for exhaust components?