Overview of the Smittybilt Wrangler Exhaust Upgrade

Upgrading your Jeep Wrangler’s exhaust system is one of the most rewarding modifications you can make. The Smittybilt Wrangler exhaust system is engineered to deliver a deeper, more aggressive exhaust note while improving exhaust flow for potential gains in horsepower and torque. Whether you own a JK, JL, or TJ model, Smittybilt offers systems that are durable, rust-resistant, and designed to withstand off-road abuse. This step-by-step guide provides everything you need for a smooth installation, from tool selection to final adjustments, so you can enjoy maximum performance and sound from your Smittybilt exhaust.

Before You Begin: Tools, Materials, and Safety

Required Tools and Materials

  • Socket wrench set – Metric and SAE sizes (typically 10mm, 13mm, 15mm, 18mm)
  • Torque wrench – For precise tightening of bolts and clamps
  • Jack and jack stands – To safely lift and support the vehicle
  • Exhaust hanger removal tool – Or a large flathead screwdriver with penetrating oil
  • Safety goggles and gloves – Protect against rust debris, sharp edges, and hot components
  • Smittybilt Wrangler exhaust system – Verify it fits your year and model
  • Penetrating oil (e.g., WD-40 or PB Blaster) – For loosening rusted bolts
  • Anti-seize compound – For bolt threads to prevent future corrosion
  • Metal file or grinder – To clean up flanges if needed

Safety Precautions

  • Park the Wrangler on a flat, level surface and engage the parking brake.
  • Disconnect the negative battery terminal to avoid accidental shorts or electrical issues.
  • Allow the exhaust system to cool completely – hot pipes can cause severe burns.
  • Use jack stands rated for your vehicle’s weight; never rely solely on a jack.
  • Work in a well-ventilated area – exhaust fumes are toxic even when the system is not running.

Removing the Old Exhaust System

Proper removal is the foundation of a clean installation. The old system may be rusted and stubborn, so patience and penetrating oil are your friends. Follow these steps in order:

  1. Spray all bolts and clamp hardware with penetrating oil. Let it soak for 10–15 minutes.
  2. Support the exhaust – Place a jack with a wood block under the muffler section to keep it from dropping suddenly.
  3. Remove the bolts connecting the exhaust pipe to the exhaust manifold (or catalytic converter, depending on your setup). Use a socket wrench and breaker bar if needed.
  4. Loosen the clamps that connect pipe sections – these are often at the axle and mid-pipe junctions.
  5. Remove the exhaust hanger isolators using the removal tool or a screwdriver. Carefully pry the rubber hanger away from the metal tab on the frame or hanger bracket.
  6. Lower the old exhaust from the rear first, sliding it out from under the vehicle. It may need to be twisted or angled to clear the axle and control arms.
  7. Inspect the old gaskets and flanges – clean off any carbon buildup or rust with a wire brush. Replace any damaged gaskets with new ones (often included with Smittybilt systems).

Installing the Smittybilt Exhaust System

Pre-Installation Checks

  • Lay out all Smittybilt exhaust components and compare them to the instruction sheet provided by the manufacturer. Confirm no parts are missing.
  • Check that the new system is compatible with your Wrangler’s driveline – especially if you have a lift kit or aftermarket suspension components that may affect routing.
  • Apply a thin layer of anti-seize compound to all bolt threads – this will simplify future removal.

Step-by-Step Installation

  1. Install the front (header or downpipe) section – If your Smittybilt system replaces components from the manifold back, start at the front. Place the new gasket against the manifold flange (or catalytic converter outlet), then attach the front pipe with the supplied bolts. Tighten to 25–30 ft-lbs (check the torque spec in the kit instructions).
  2. Add the mid-pipe section – Slip the mid-pipe over the front pipe, aligning the overlapping joints. If a clamp is provided, leave it slightly loose to allow for adjustment. Ensure the pipe is centered and not contacting the transmission crossmember or skid plates.
  3. Install the muffler/cat-back section – Position the muffler and rear tailpipe assembly. Most Smittybilt systems use a straight-through muffler for optimal flow and sound. Slide the inlet pipe into the mid-pipe and loosely install the clamp.
  4. Attach the exhaust hangers – Place the rubber isolators onto the metal hanger tabs welded to the new exhaust. The isolators should be firmly seated. Check that the tailpipe outlet is positioned correctly – usually exiting behind the rear tire or out the side, depending on your Smittybilt model.
  5. Adjust alignment and tighten – Before final torque, shift the exhaust sections until there is at least 1 inch of clearance from the frame, shocks, brake lines, and suspension arms. Rotate the tailpipe tip to the desired angle. Once aligned, tighten all clamps to the manufacturer’s specification (typically 30–40 ft-lbs for 2.5” clamps). Re-tighten flange bolts.
  6. Torque all fasteners – Use your torque wrench for a final pass on all bolts. For clamp bolts, ensure they are snug but not overly tight to avoid crushing the pipe.

Important Clearance Tips

  • Check near the fuel tank heat shield – Ensure the exhaust does not touch the shield; a gap of 1/2–1 inch is ideal to prevent vibration noise.
  • Watch the track bar and sway bar links – When articulating the suspension, the exhaust should not come into contact. Test by cycling the suspension by hand if possible.
  • Tailpipe exit – If your system exits under the rear bumper, confirm the tip does not interfere with spare tire carriers or aftermarket bumpers.

Final Adjustments and Testing

  1. Tighten everything once more after the initial test fit. Vibrations can cause loosening, so a second check is wise.
  2. Reconnect the battery and start the engine. Let it idle for a minute – you will immediately hear the new Smittybilt tone. Listen for any rattles or metallic contact.
  3. Inspect for exhaust leaks – With the engine running, feel around all joints (while avoiding hot surfaces) for any puffing air. A small leak will often produce a ticking sound and may smell of exhaust fumes. Tighten clamps or replace gaskets if needed.
  4. Take the Wrangler for a short test drive – Drive over bumps and through turns to verify no pipe contact. Accelerate and decelerate to hear the full sound range. Listen for drone at highway speeds – Smittybilt systems are designed to minimize drone, but verify it meets your expectations.
  5. Re-check all hardware after 100 miles – Heat cycles will settle the system. Retorque all bolts and clamps to ensure a lasting seal.

Troubleshooting Common Installation Issues

Exhaust Drone or Excessive Noise

If the sound is louder than expected, check for leaks at the manifold connection or at any slip joint. Some Smittybilt systems are performance-oriented and will be louder than stock – this is normal. For drone on the highway, ensure the tailpipe tip is not pointing directly out the side (which can bounce sound off the ground) – rotating it downward slightly can help.

Vibration or Rattling

Inspect all hanger isolators: they must be fully seated and not torn. If the exhaust touches any part of the chassis, you can gently dimple the pipe with a drift punch or use a rubber isolator spacer to increase clearance. Never bend the pipe excessively – this can restrict flow.

Difficulty Slipping Pipes Together

If the pipe ends are too tight, use a fine file or sandpaper to smooth any burrs. A small amount of soapy water or lubricant (not oil near a potential heat source) can ease assembly. For Smittybilt systems with band clamps, ensure the slotted ends are facing the correct direction.

Performance Benefits and Sound Character

The Smittybilt Wrangler exhaust is more than just a louder system. By increasing pipe diameter (typically 2.5 inches) and using a free-flowing muffler, it reduces backpressure, allowing the engine to breathe more efficiently. This often results in a 5–10 horsepower increase on naturally aspirated engines, with a commensurate torque bump in the mid-range. The sound is deep and aggressive without the raspy tone of cheaper systems. Many off-roaders appreciate that the Smittybilt exhaust retains a manageable sound level for daily driving while delivering a commanding growl under throttle.

Maintenance and Longevity Tips

  • Regularly inspect all hangers and isolators – Rubber components degrade over time and can allow the exhaust to sag.
  • Clean the exhaust tip with a dedicated metal polish to prevent corrosion and maintain appearance. Use a non-abrasive cleaner for coated tips.
  • Check bolt torque annually – Especially after a hard off-road trip where the system may have been jarred.
  • Apply anti-seize to threads during any maintenance removal – this prevents the stainless steel hardware from galling.
  • Watch for rust – While Smittybilt uses aluminized or stainless steel materials, road salt and moisture can still cause surface rust over many years. If you live in a snow belt, consider rinsing the underside after winter drives.

Final Thoughts

Installing a Smittybilt Wrangler exhaust is a straightforward weekend project that significantly upgrades your Jeep’s sound and performance. By carefully removing the old system, taking time with alignment, and using the right torque specifications, you can ensure a leak-free, rattle-free installation that will serve you for years. For more details on specific system models and fitment, visit the Smittybilt official website or consult the Jeep Forum community for model-specific advice. Enjoy the enhanced driving experience and the roar of your upgraded Wrangler.