New exhaust replacement catalytic converters to tailpipe

Tiny
KLHUDOCK64
  • MEMBER
  • 2004 JEEP LIBERTY
  • 3.7L
  • 6 CYL
  • 4WD
  • AUTOMATIC
  • 156,000 MILES
Okay, so when I purchased this used there were zero catalytic converters on this. Someone had just ran flex pipe and it's all full of holes and leaking throwing 02 codes etc. I bought it in PA I'm from NY with mandatory emissions at inspection. I've purchased left and right converters y pipe muffler tailpipe. I can't seem to find any diagrams or YouTube videos on this. I'm going crazy trying to figure out what clamps I need and how many. I also believe there is a small exhaust pipe to the muffler I'm overlooking. I believe I need a few V clamps springs and bolts 2 u bolt clamps and a gasket. I have 2 new downstream sensors as one is welded to the flex pipe on there so I just ordered 2 new ones just in case. I'm just trying to make sure I have all the parts needed before I start this job I'm pretty sure I can get someone to help. I'm tired of buying used vehicles every so often so I'm just going to put the money into this and hopefully keep it for 3 to 5 years without starting over on another used vehicle. Parts for this are very expensive I have found out! Any diagrams or input on a complete exhaust replacement from converters to tailpipe would be appreciated and definitely help. I probably could have just used a universal cat replacement but I believe in just doing it the right way as long as I have the extra money right now. Lord knows this vehicle is breaking the bank. Lol
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Thursday, April 29th, 2021 AT 1:17 PM

50 Replies

Tiny
STEVE W.
  • EXPERT
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.
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Thursday, April 29th, 2021 AT 4:52 PM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Thursday, April 29th, 2021 AT 9:26 PM
Tiny
STEVE W.
  • EXPERT
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.
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Thursday, April 29th, 2021 AT 10:46 PM
Tiny
KLHUDOCK64
  • MEMBER
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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Friday, April 30th, 2021 AT 12:05 AM
Tiny
STEVE W.
  • EXPERT
Being a NYer myself I know what this states roads do to vehicles so I try to help save them.
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Friday, April 30th, 2021 AT 1:11 AM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Friday, April 30th, 2021 AT 4:50 AM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Friday, April 30th, 2021 AT 7:02 PM
Tiny
KLHUDOCK64
  • MEMBER
Would this be the correct part I need for the exhaust if it is not on the muffler?
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Friday, April 30th, 2021 AT 7:46 PM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Friday, April 30th, 2021 AT 8:34 PM
Tiny
STEVE W.
  • EXPERT
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.
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Saturday, May 1st, 2021 AT 12:01 AM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Saturday, May 1st, 2021 AT 7:01 AM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Saturday, May 1st, 2021 AT 7:20 AM
Tiny
STEVE W.
  • EXPERT
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.
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Saturday, May 1st, 2021 AT 9:01 AM
Tiny
KLHUDOCK64
  • MEMBER
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
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Saturday, May 1st, 2021 AT 7:39 PM
Tiny
STEVE W.
  • EXPERT
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.
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Saturday, May 1st, 2021 AT 8:38 PM
Tiny
KLHUDOCK64
  • MEMBER
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!
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Sunday, May 2nd, 2021 AT 12:48 AM
Tiny
JOE F
  • EXPERT
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
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Tuesday, May 4th, 2021 AT 9:38 PM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Wednesday, May 5th, 2021 AT 12:25 AM
Tiny
JOE F
  • EXPERT
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
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Wednesday, May 5th, 2021 AT 7:45 PM
Tiny
KLHUDOCK64
  • MEMBER
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.
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Wednesday, May 5th, 2021 AT 7:53 PM

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