Novak Conversions Jeep Wrangler TJ engine mounts

Best choice for a complete 4 cylinder exhaust system (header to tail pipe)?

Tray Burge

Tray Burge

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Couldn't find the post to answer my question, so...
like the title says, I'm in the market for a complete stainless steel, header to tail pipe system for my 97 4cy, 5speed TJ?
Just want a quite, quality system that'll hold up, my current one is shot and rot.
Any recommendations on a tried and true system for fitment and compatibility?
 
Starting with the manifold the OEM Cast Iron although generally unavailable is the most cost effective if you can locate one, otherwise the aftermarket CI manifolds are total crap and should be avoided. I am running a set of Ebay stainless OEM pattern headers that run about $100 or so and on the high end is the Banks SS OEM pattern which is a quality product. Beyond that I am a fan of the NAPA direct replacement Stainless muffler (all stainless) and it's not pricey. I'm still running the original down pipe and Cat.
 
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TJ4Jim said:
Starting with the manifold the OEM Cast Iron although generally unavailable is the most cost effective if you can locate one, otherwise the aftermarket CI manifolds are total crap and should be avoided. I am running a set of Ebay stainless OEM pattern headers that run about $100 or so and on the high end is the Banks SS OEM pattern which is a quality product. Beyond that I am a fan of the NAPA direct replacement Stainless muffler (all stainless) and it's not pricey. I'm still running the original down pipe and Cat.
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Hey Jim, thanks for chiming in. Does anybody make a complete system in stainless I can order or am I going to have to piece mill this system together. I really don't wanna fool around with trying to find an old cast manifold if I don't have to? I really want total stainless all the way through. I did see the Banks products on Summit Racing by the way, but no complete systems I don't think by them?
 
Tray Burge said:
Hey Jim, thanks for chiming in. Does anybody make a complete system in stainless I can order or am I going to have to piece mill this system together. I really don't wanna fool around with trying to find an old cast manifold if I don't have to? I really want total stainless all the way through. I did see the Banks products on Summit Racing by the way, but no complete systems I don't think by them?
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Yeah I wish, for the most part it's generally Cat back systems (see link for reference) which leaves the downpipe, cat and header to source individually. I have to say though that the OEM steel downpipe if pretty freaking well made and as much as I like stainless I never saw the need to replace it for show.


https://www.extremeterrain.com/wrangler-jeep-tj-cat-back-systems.html
 
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I would stick with OEM from the head to the cat and then there are stainless aftermarket options from there.
 
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That's my point guys, I don't want to be looking, seeking and then spending stupid money if I can find a complete system already made. Is the Banks header going to fit correctly or does it leak? Banks also makes the other components too I think?
EDIT: Maybe I need to consider keeping the stock cast manifold if it's the best choice based on y'alls call (I think it's still okay, no holes?) and then just replace everything back from there with stainless, would this be a better plan?
 
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TJ4Jim said:
Yeah I wish, for the most part it's generally Cat back systems (see link for reference) which leaves the downpipe, cat and header to source individually. I have to say though that the OEM steel downpipe if pretty freaking well made and as much as I like stainless I never saw the need to replace it for show.


https://www.extremeterrain.com/wrangler-jeep-tj-cat-back-systems.html
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Okay, that was informative. So as long as my stock manifold isn't trashed, do you have any recommendations on the cat-forward system in stainless?
 
I've heard pretty good things for the Walker SS exhaust system. From the manifold back. New cats and muffler.
On the other hand, I have had to use the Walker aluminized system on a Nissan PU that started to rust up within 6 months. It was a bolt together with a gasket in between pieces. And the bolt holes in pipe A were different sized than the holes in pipe B where they connected.
I will be needing a complete system too. But for an 06 4.0 and am wondering what to do too.
 
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Goatman said:
I've heard pretty good things for the Walker SS exhaust system. From the manifold back. New cats and muffler.
On the other hand, I have had to use the Walker aluminized system on a Nissan PU that started to rust up within 6 months. It was a bolt together with a gasket in between pieces. And the bolt holes in pipe A were different sized than the holes in pipe B where they connected.
I will be needing a complete system too. But for an 06 4.0 and am wondering what to do too.
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Thanks Goat, I'll look at that too.
Anybody got any feedback on this system in stainless?
 
Tray Burge said:
Thanks Goat, I'll look at that too.
Anybody got any feedback on this system in stainless?
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I am not aware of any SS down pipes or complete packaged systems for the 2.5 but I am familiar with the Walker SS muffler which is why I suggested the NAPA as it is basically identical to the Walker except it is actually all SS unlike the Walker that is only SS internals. Banks headers are top quality OEM pattern but if you have the OEM cast manifold still in one piece then I would just reuse that.
 
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TJ4Jim said:
I am not aware of any SS down pipes or complete packaged systems for the 2.5 but I am familiar with the Walker SS muffler which is why I suggested the NAPA as it is basically identical to the Walker except it is actually all SS unlike the Walker that is only SS internals. Banks headers are top quality OEM pattern but if you have the OEM cast manifold still in one piece then I would just reuse that.
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This is great information, now I know where to start and which direction to go! Thanks Jim for all your input along with the others too.
 
I just put in a new exhaust system on my '97 2.5L 5-spd. Here is what I bought...

https://www.jegs.com/i/Crown-Automo...=Transactional&utm_content=Order+Confirmation
The engine still has its original exhaust manifold, Installer had to remove the OE studs and use longer bolts/nuts as the flange design was such that the OE studs were too short. Otherwise, it was pretty straightforward install. I think the pipes are aluminized, not SS. Price reflects that. However, I am sure I will get plenty of years out of it.

I also bought new NTK O2 sensors to go with it. I can already tell that it is running better than before.
 
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TJ4FUN said:
I just put in a new exhaust system on my '97 2.5L 5-spd. Here is what I bought...

https://www.jegs.com/i/Crown-Automo...=Transactional&utm_content=Order+Confirmation
The engine still has its original exhaust manifold, Installer had to remove the OE studs and use longer bolts/nuts as the flange design was such that the OE studs were too short. Otherwise, it was pretty straightforward install. I think the pipes are aluminized, not SS. Price reflects that. However, I am sure I will get plenty of years out of it.

I also bought new NTK O2 sensors to go with it. I can already tell that it is running better than before.
Click to expand...
Thanks TJ4, I'll take a look. I know it has to be all stainless for me to buy it, maybe they'll have a version in SS too.
 
About to pull the trigger on a whole new exhaust system, but...?
My jeep turns 25 yo this year, so next year I won't need an emissions test where I live so I was considering going catless on my new system.
Good idea? Bad idea? Good, but will I'll need to do anything in addition to make it work with my PCM?
Comments?
 
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