Help Me Install This Exhaust System ('97 2.5L)

SSTJ

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Lifetime Supporting Member
Joined
Aug 24, 2019
Messages
3,344
Location
South Carolina
Other than replacing my exhaust manifold, I have never worked on an exhaust system.
I think my catalytic converter needs to be replaced, and I found this for $80.
So instead of trying to replace the cat alone, I'd like to just replace the entire system.

I think this will be easy? Please tell me if I’m missing something.
  • Remove transmission skid (use jack to support transmission).
  • Unplug both 02 sensors (I have only two on the 2.5).
  • Detach down-pipe from manifold (done this before, bolts should be good).
  • Detach all exhaust hangers and let the whole exhaust system drop to the ground.
  • Move 02 sensor to new down-pipe (I just recently replaced it).
  • Put new downstream 02 sensor in new catalytic converter.
  • Attach new down-pipe and cat (currently one piece) to exhaust manifold with a new ring seal.
  • Attach muffler to cat with band clamp.
  • Attach tail pipe to muffler with band clamp.
  • Replace transmission skid.
Anything else I should do while I’m at it?
 
Last edited:
All my band clamps are leaking...might want to weld em. Minor issue.

Hmm, that's discouraging. I asked here and the consensus seemed to be that they work fine.

I'll have no choice for now, since I can't weld. But I could have a friend do it eventually.