Exhausted! (Question about exhaust system)

Discussion in 'KJ General Discussion' started by zzAMBIENzz, Mar 23, 2019.

  1. zzAMBIENzz

    zzAMBIENzz New Member

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    Any idea if the complete exhaust system from a '05 will fit, or can be made to fit a '04?

    From what I can tell, the '04 has a one-off exhaust system. My Auction Nightmare Liberty was found to have the converters punched out. I have found a '05 being parted out, but it has the one piece, welded system, where the '04 has the 3 piece, clamped system. I don't mind fabbing mounts if necessary, but my concern is if the downpipes will match up with the manifolds and if anything else changed on the undercarriage that would interfere with the newer system.
     
  2. zzAMBIENzz

    zzAMBIENzz New Member

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    Images for clarification.

    '05 system
    [​IMG]

    '04 Driver Side
    [​IMG]

    '04 Passenger Side


    [​IMG]
     
  3. tommudd

    tommudd Moderator Staff Member Moderator

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    You can not really go off of most pictures on rock auto or any other site, they use various pictures from different manufactures so all the same but different
    I have an 04 and 05 and never noticed any differences
    Since you will be changing everything then only difference would be from where they bolt onto the exhaust manifolds I would think
    Until I crawl under both of mine can't say for sure though
     
  4. zzAMBIENzz

    zzAMBIENzz New Member

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    I do know on my '04 the system is the more "modular" type, and the owner of the '05 parts car did say that his was a single piece that had both converters.

    On one hand, I don't see how the end result could be that much different, since its the same engine in the same body. At worst, I would expect to maybe have to fab up a new hanger. On the other hand ... this project has literally been both a nightmare, and a huge money pit, and the idea of spending ANOTHER $100 on something that may or may not even fit, let alone fix my problem is daunting.

    I swear I have never just wanted to bash a vehicle with a ball bat as much as I do with this one.

    I guess, if nothing else, I should be able to recoup my money back just scrapping the converters if it doesn't work.
     
  5. Royy

    Royy Full Access Member

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    The downpipes will not match up with the exhaust manifolds. The 02-04 uses a V-clamp system. On the 05+, both the downpipe and the exhaust manifold have flanges that get bolted together. If you want to attach an 05+ downpipe to an 02-04 exhaust manifold, there is no way to connect them

    On the '05 the upstream O-2 sensors are mounted lower than they are on the 02-04. I don't know if that different placement would interfere with any other parts on the 02-04. I'm not familiar enough with the 02-04 to be able to say with certainty.
     
  6. JasonJ

    JasonJ Full Access Member

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    I hear ya... I was that way with my 94 Grand Marquis.. but I loved that car, and it was worth it in the end. Just remember, it is not the vehicle's fault.. some idiot owner or engineer caused this..

    ^ This.. and it's evident in the images that were posted. You can visibly see the height differences in the O2 bungs- not that I think that will cause an issue, but look at how and where they connect to the manifolds. Not compatible.

    So at minimum, you would have to swap exhaust manifolds over. If that's doable for you, go for it.. might need to fab a hanger or two underbody.

    Personally, I love exhaust v-clamps.. bolt on flanges break, studs and bolts rust, seize, and are a pain to cut off in tight places, exhaust flange gaskets blow out too often.. flanges corrode their welds and fall off.. ugh. no.

    V clamps, when they get old and crusty and fail, often don't do or have damage to the flared ends of the pipe. Just replace the clamp and go. Easier to fit in tight spaces, faster installation, no worries about whether it's torqued enough and will leak or not. Kind of go/no-go.
     
  7. renegade 04

    renegade 04 Full Access Member

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    The 2005 exhaust will fit it you change out the exhaust manifolds to be either JBA headers or the 2005 exhaust manifolds. I change to the new style on my 2004 when I got the JBA headers, the only issue that I had was that I needed to add a heat shield between the header and the firewall on the passengers side.