heat shield and muffler issues...
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JK Enthusiast
Joined: Nov 2009
Posts: 118
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From: Johnson City, Tennessee
heat shield and muffler issues...
A few weeks ago, the 08 Sahara started to rattle, and rattle and rattle. The heat shield above the muffler had failed by fatigue at the retaining bolts. My first thought was just to remove the heat shield, but then I remember my wife cooking and melting the rear compartment floor of her Pathfinder when the tailpipe failed on a trip to Texas and she ignored it. This jeep is way to nice for that...
So, Four Wheel parts had the heat shield CHEAP, like $25 with shipping so I ordered that. Then I realized that to get to the heat shield the muffler had to come out and I had the feeling that pulling the muffler was a one shot deal, as in once the muffler comes out, the same muffler was never going to go back on.
Rock Auto supplied a Walker muffler, stock style, a clamp, and rubbers and today was the day. The die grinder got the rubbers off easy enough, the clamp got slit next, and the muffler pipe that connected to the tail pipe was slit and opened up with a chisel.
Believe it or not, but I was able to wire brush the heat shield studs (welded to the rear floor pan) and was able to get the POS kwiknuts off with a 11mm impact socket and air gun. Then more wire brushing, new real nuts and washers from inventory (10mm head metric), two washers for extra support, plenty of anti-seize and back on.
The muffler took a little bit of playing. The tail pipe got sanded clean and heavily coated with anti-seize, the left side rubber had to go on muffler first, then the mount, the right side was mount, then muffler. All about two hours and the rattle is gone...
Tips and tricks: plenty of WD40 lubricates the rubbers, slit the clamp and pipe carefully to avoid gouging the tail pipe, and jack and block of wood supports the muffler until the rubbers are on. Wear old clothes and good safety glasses, plenty of rust to the face. No heavy hammer, no heat and no fuss. The heaviest hammer used was 16oz ballpeen to drive the chisel. A small pry bar came in handy to open the muffler inlet pipe up.
Total cost for all parts and supplies was under $150, so I call that a success. Now the jeep is as quiet as stock. The only real noise is the crunch of the 265/70R17 studded snow tires. The 17" rims have a much better tire selection than the stock 18".
The wife's comment? Why didn't you spend the EXTRA money for the upgraded glasspack twin outlet muffler...
Now, does anyone want a heavy, rusty muffler with the inlet split open?
Howard
So, Four Wheel parts had the heat shield CHEAP, like $25 with shipping so I ordered that. Then I realized that to get to the heat shield the muffler had to come out and I had the feeling that pulling the muffler was a one shot deal, as in once the muffler comes out, the same muffler was never going to go back on.
Rock Auto supplied a Walker muffler, stock style, a clamp, and rubbers and today was the day. The die grinder got the rubbers off easy enough, the clamp got slit next, and the muffler pipe that connected to the tail pipe was slit and opened up with a chisel.
Believe it or not, but I was able to wire brush the heat shield studs (welded to the rear floor pan) and was able to get the POS kwiknuts off with a 11mm impact socket and air gun. Then more wire brushing, new real nuts and washers from inventory (10mm head metric), two washers for extra support, plenty of anti-seize and back on.
The muffler took a little bit of playing. The tail pipe got sanded clean and heavily coated with anti-seize, the left side rubber had to go on muffler first, then the mount, the right side was mount, then muffler. All about two hours and the rattle is gone...
Tips and tricks: plenty of WD40 lubricates the rubbers, slit the clamp and pipe carefully to avoid gouging the tail pipe, and jack and block of wood supports the muffler until the rubbers are on. Wear old clothes and good safety glasses, plenty of rust to the face. No heavy hammer, no heat and no fuss. The heaviest hammer used was 16oz ballpeen to drive the chisel. A small pry bar came in handy to open the muffler inlet pipe up.
Total cost for all parts and supplies was under $150, so I call that a success. Now the jeep is as quiet as stock. The only real noise is the crunch of the 265/70R17 studded snow tires. The 17" rims have a much better tire selection than the stock 18".
The wife's comment? Why didn't you spend the EXTRA money for the upgraded glasspack twin outlet muffler...
Now, does anyone want a heavy, rusty muffler with the inlet split open?
Howard