Hello my fellow Jeepers! What is the best exhaust system for Jeep Wrangler YJ? Well, that depends are you wanting a new stock replacement exhaust or a high performance system to get more power and better fuel mileage? There are so many choices is can be confusing and overwhelming!
I have been in the game of building cars, trucks, motorcycles and Jeeps for just over 30 years. So, I have seen many types and brands of exhaust systems and individual exhaust components such as headers, catalytic convertors, mufflers and exhaust pipe. Some I liked .. Some I loved .. Some I wouldn’t put on a lawnmower!!
What is the best exhaust can be a matter of opinion. Some people like Flowmaster, some like Dynomax or Borla and so many others. Then there are the Jeep owners who prefer having a stock replacement system under their rig.
Then there is the exhaust header. Some want a factory replacement, some people like the high performance stainless steel headers. Again .. it’s a matter of personal taste.
One thing is for sure. No matter what brand we like, we want quality parts that last!
So, with that being said, I have brought together a list of the best exhaust systems for your Jeep YJ. You pick your favorite brand! Add B000N5LGD2 to exhaust resource page
Best Exhaust System for Jeep Wrangler YJ – Components
Most people don’t purchase a complete kit from header to tail pipe. They usually replace a header, muffler or catalytic converter individually because they typically wear out faster than the the exhaust pipe. So, I’ll save you a little time and start out the list as components.
Jeep Wrangler YJ Exhaust manifolds
The exhaust header or manifold is the #1 source for exhaust leaks for the Wrangler YJ and XJ Cherokee. Most all the factory manifolds eventually crack right where the primary tubes meet the collector. Sometimes the leak is so subtle you don’t really notice it over the sound of the engine running. Other times it crack bad enough that it has that whistling popping sound all the time. So annoying!
The Wrangler YJ engines were either the 2.5 liter 4 cylinder or the 4.0 liter 6 cylinder. The early YJs 1990 and older had 4.2 liter as the 6 cylinder option. I’m going to create the list for each engine. If you order from the Amazon link please verify that it fits your particular model.
If you opt for one of the performance headers, expect better performance, better fuel mileage and really cool exhaust notes!
Jeep Wrangler YJ Exhaust Manifold – 2.5 liter squirrel power
Dorman factory replacement
If you wanted a direct factory replacement, here is what you would get. The little cast iron 4 cylinder exhaust manifolds are way less prone to cracking. But occasionally the original factory cast iron may crack. It’s typically due to uneven torquing of the bolts with the heat expansion. So, if you use this manifold to repair your Jeep, do yourself a favor and make sure all your manifold bolts are torqued exactly the same. Add B000C17H08 resource.
Be sure to order a new gasket. The gasket for the 2.5 and 4.0 seal the exhaust and the intake manifold to the cylinder head. Add B007DKPM4Y
Jeep Wrangler YJ Exhaust Manifold – 4.0 liter 6 cylinder
For the Jeep Wrangler YJ, the 4.0 liter inline 6 cylinder is the most popular of the 3 engines mentioned above. The tough, reliable and super durable 6 cylinder came on the Wrangler YJ scene in 1991. This was the first fuel injected 6 cylinder engine. It has the most simplistic injection system of any vehicle I’ve ever worked on. The 4.0 Jeep engine is my favorite inline 6 cylinder ever made. The engine picture with signatures all over it is the 5 millionth 4.0 liter engine made. Nope .. that’s not a typo .. that is 5,000,000+ 4.0 liter engines made!!
Jeep Wrangler 4.0 liter exhaust manifold factory replacement
Unlike the 2.5 liter 4 cylinder, there are lots of choices of exhaust manifolds and headers for the 4.0 liter inline 6.
Building the best exhaust system for your Jeep Wrangler YJ, you gotta start with the exhaust manifold for stock replacement or header if you are going for the performance.
Now the modding gear head that I am I wanna start with the performance stuff first. Alas, I’ll do this in logical order.
Standard steel Stock style exhaust manifold
With 95%+ of the factory exhaust manifolds cracking, many aftermarket manufactures are addressing this issue by putting flex points within the long primary tubes. This is supposed to help take some of the vibrations away from where the primary tubes are welded to the collector. If you look at the Amazon picture link of the manifold kit you can see the flex joints in the long primaries. Click here to see the current price of the Jeep Wrangler exhaust manifold. It makes total sense that the flex joints would work simply because long section of anything structural has more leverage and movement than any short spans of the same structural material. Add B001O9ZJT8
*** Just a quick side note .. I work in the IT field for a living now. Before IT I worked in the product engineering field for over 12 years. Structural loading tests was part of what I did at the time. Yep .. I got to design stuff, then break stuff and got PAID FOR IT! Sweet! Since at a very young childhood age I’ve been addicted to cars, trucks, Jeeps and motorcycles.
Jeep Wrangler 4.0 liter exhaust header performance replacement
Yeaaaa .. I get to write about performance exhaust parts now! I love modding stuff for more power. That is exactly why my YouTube channel is called Power Addicts.
OK .. get back on track! Now we are at the the performance exhaust headers for the Jeep Wrangler 4.0 liter. I’m gonna list a few different options. Some exit like the factory exhaust manifold .. some are nothing like the factory unit. With anything performance oriented there is always the possibility of having to do a little or a lot fabrication work. Above all else, I’m not gonna BS you!!
Banks Torque Tube System
Here we go .. getting into parts that give even better performance, better fuel mileage and longer life.
Banks products is largely know for their turbo charger upgrades for the full size diesel truck crowd. Their manifold and turbo upgrades have been the industry leader for producing INSANE amounts of torque for the full size truck in-line 6s. Reviews all around the internet states that the performance gains from this 4.0 exhaust header is totally worth the bit higher price tag!
With the power Banks extracts from the big 6’s, it just makes sense that they can do the same for the Jeep inline 6’s as well.
These headers have TIG welded 4090 Stainless Steel and 1/2″ thick flanges to ensure durability. Even though the price is higher that the ones above, it is well worth the money! How much is it? Click here to check Amazon for current pricing.