caesar1812

If you have replaced your cat assembly, any advice would be greatly appreciated!

I recently began an attempt to replace my cat assembly with a new part. This is on a '09 Wrangler X Unlimited. Was using the How-To posted on this site as a guide but ran into some issues.

First, the How-To notes that the crossbar could be removed, but shouldn't be necessary. I am finding that it absolutely has to be removed in order to slide the Y-pipe out of the exhaust pipe and lower the assembly. There's just too much length past that crossbar to the exhaust and it prevents the Y from coming down and out with the rest of the ridiculously large assembly. In fact, I'm not even sure the upper cat can will clear the front drive shaft when I finally am able to get the lower end past that crossbar. Also, the How-To neglects to mention that the transmission rests on that crossbar, requiring a lot more work to remove it than expressed in that How-To.

Does anyone have experience with this and can tell me if they found it necessary to remove the crossbar and/or the front drive shaft? I'm about to cut the old assembly out, but I may still be stuck having to remove things to get the new one in. Any advice is much appreciated!

AJ_

I did it and it was pretty hard but I did manage to wedge the thing up in there. Sorry that's the best help I can give cause I don't remember lol

redfiveshoe

I did this recently and had to remove the crossmember while holdng the transmission up with a jack. Total PITA, but finally got it. I also had to buy longer bolts to go in where it attaches to the header. The stock bolts wont allow you tighten it enough. Good luck

OverKill

I looked at possibly doing that and it looked difficult and it looked like the cross member had to be replaced. Personally, about the bolts, I would cut them off and replace with new. Just seems easier. But my problem wound up being the O2 sensors, that cleared up my cat code. Good luck

lonesometree

I did this repair a couple years ago. I did not remove the crossmember on disassembly because I cut the old exhaust out in 4 pieces. I thought I was saving myself time but I was wrong because it is absolutely necessary to remove in order to get new y-pipe in. I did have to unbolt the driver side upper control arm also to get cats out and back in. Not a big chore though. Go ahead and remove both inner fenders as well to make life easier. This will provide better access to remove and replace bolts holding y-pipe to manifold. I didn't do any of this at first and the removal was a nightmare for a brief period. But I did remove everything before installing new cats and the job was a breeze. I was being lazy and it busted my balls. So take my advice. Don't be lazy. Ha. If you prepare properly it's really not a hard job. Good luck!

lonesometree

P.S. I think I did a vague write up on this back then. So if it was mine that confused you, I apologize.