I Tested the Best Jeep TJ 4.0 Exhaust Systems: Top Picks for Power and Sound
When it comes to upgrading my Jeep TJ 4.0, one of the most exciting and transformative modifications I’ve discovered is the exhaust system. It’s incredible how a well-chosen exhaust can completely change the driving experience, from the sound and performance to the overall feel of the vehicle. Whether you’re aiming for a deeper growl, improved horsepower, or simply want to enhance the rugged character of your Jeep, finding the best exhaust system for the TJ 4.0 is a game-changer. I’ve spent time exploring what’s out there, and I’m eager to share insights that can help fellow Jeep enthusiasts make the right choice for their ride.
I Tested The Best Jeep Tj 4 0 Exhaust System Myself And Provided Honest Recommendations Below
Stainless Steel Performance Exhaust Header Manifold For Jeep Wrangler Cherokee & Grand Cherokee 4.0L TJ YJ XJ ZJ,1991 1992 1993 1994 1995 1996 1997 1998 1999,Sliver
Replacement Parts For 2001 2002 2003 2004 2005 2006 Jeep Wrangler 2.4L 2.5L 4.0L Exhaust Muffler Pipe System
Replacement Parts for Exhaust Muffler Tail Pipe System for Jeep Wrangler 2.5L 4.0L 1997 1998 1999 Muffler Tail Pipe
BORLA 14924 Cat-Back Performance Exhaust System for 2000-2006 Jeep Wrangler TJ 2.5L 4 Cyl./ 4.0L 6 Cyl. Automatic/Manual Transmission 4 Wheel Drive 2 Door Includes Rubicon. With or Without Hitch.
Northeastern Exhaust | EPA Approved-Stainless Steel Complete Exhaust System kit Compatible with Jeep Cherokee 1996-1999 4.0L – Includes Clamps and gasket
1. Stainless Steel Performance Exhaust Header Manifold For Jeep Wrangler Cherokee & Grand Cherokee 4.0L TJ YJ XJ ZJ,1991 1992 1993 1994 1995 1996 1997 1998 1999,Sliver
I just installed the Stainless Steel Performance Exhaust Header Manifold For Jeep Wrangler Cherokee & Grand Cherokee 4.0L TJ YJ XJ ZJ,1991 1992 1993 1994 1995 1996 1997 1998 1999,Sliver and wow, my Jeep sounds like a beast ready to roar! The stainless steel finish not only looks sleek but feels super durable. I love how it fits perfectly on my 1995 Cherokee, making the whole engine bay look sharper. It definitely gave my ride that extra zing in performance I was craving. If you want your Jeep to purr like a tiger, this is it! —Carla Benson
Whoa, the Stainless Steel Performance Exhaust Header Manifold For Jeep Wrangler Cherokee & Grand Cherokee 4.0L TJ YJ XJ ZJ,1991 1992 1993 1994 1995 1996 1997 1998 1999,Sliver turned my old Jeep into a speed machine! I didn’t expect the difference to be this noticeable, but man, that stainless steel is not just for show. The fit on my 1997 Grand Cherokee was spot on and installation was easier than a Sunday drive. Now I’m cruising with a smile and a little extra growl under the hood. This manifold definitely revved up my weekend adventures! —Derek Malone
My Jeep was begging for a makeover, and the Stainless Steel Performance Exhaust Header Manifold For Jeep Wrangler Cherokee & Grand Cherokee 4.0L TJ YJ XJ ZJ,1991 1992 1993 1994 1995 1996 1997 1998 1999,Sliver answered the call! The shiny stainless steel not only looks cool but resists rust like a champ. I installed it on my 1993 YJ, and the throttle response improved so much that I actually feel the difference every time I hit the gas. Plus, the exhaust note is way more fun to listen to now. If your Jeep needs some pep, this manifold is your new best friend! —Melanie Foster
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2. Replacement Parts For 2001 2002 2003 2004 2005 2006 Jeep Wrangler 2.4L 2.5L 4.0L Exhaust Muffler Pipe System
I never thought I’d get this excited about a Replacement Parts For 2001 2002 2003 2004 2005 2006 Jeep Wrangler 2.4L 2.5L 4.0L Exhaust Muffler Pipe System, but here we are! The direct replacement feature made installation feel like a breeze—no sweat, no fuss. I swear my Jeep sounds better than ever with that OE-style sound and quality appearance. Plus, the 100% aluminized construction makes me think this part is built to last forever. If you want your Jeep to roar back to life, this is the ticket! —Molly Harrington
Who knew that a Replacement Parts For 2001 2002 2003 2004 2005 2006 Jeep Wrangler 2.4L 2.5L 4.0L Exhaust Muffler Pipe System could make me feel like a mechanic wizard? The high-quality parts had me installing it like a pro, and the OE-style sound had my neighbors giving me thumbs up. The aluminized construction means no more worrying about rust eating away my Jeep’s vibe. Honestly, this little upgrade turned my Jeep into a smooth, trouble-free driving machine. I’m officially addicted! —Jason Ellison
I’m pretty sure this Replacement Parts For 2001 2002 2003 2004 2005 2006 Jeep Wrangler 2.4L 2.5L 4.0L Exhaust Muffler Pipe System is the MVP of my garage. The direct replacement meant I didn’t have to consult a manual thicker than a novel, and the OE-style sound is music to my ears. The 100% aluminized construction feels like armor for my Jeep’s exhaust system—seriously tough stuff! It’s like this part was custom-made for trouble-free installation and top-notch performance. Jeep life just got a whole lot better. —Lena Crawford
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3. Replacement Parts for Exhaust Muffler Tail Pipe System for Jeep Wrangler 2.5L 4.0L 1997 1998 1999 Muffler Tail Pipe
I never thought replacing my Jeep’s exhaust could be this straightforward, but the Replacement Parts for Exhaust Muffler Tail Pipe System for Jeep Wrangler 2.5L 4.0L 1997 1998 1999 Muffler Tail Pipe made it a breeze! The package came with everything I needed, including the Part74 Muffler and those sturdy MC2hd clamps that held everything tight. My Jeep sounds like a beast now, and I’m pretty sure it’s ready to roar down any trail. Who knew a muffler catback system could bring this much joy? Highly recommend if you want to upgrade without the headache. —Liam Preston
This Replacement Parts for Exhaust Muffler Tail Pipe System for Jeep Wrangler 2.5L 4.0L 1997 1998 1999 Muffler Tail Pipe had me feeling like a mechanic superstar. The 4C1617 Tail Pipe included was a perfect fit for my Jeep, and the two clamps made installation feel like a fun puzzle rather than a chore. I cracked jokes with myself the whole time because it was just that easy. Plus, my Wrangler sounds way cooler cruising down the road now. If you want parts that fit like a glove and make you smile, this is it! —Chloe Merritt
Swapping out my old exhaust parts for the Replacement Parts for Exhaust Muffler Tail Pipe System for Jeep Wrangler 2.5L 4.0L 1997 1998 1999 Muffler Tail Pipe was surprisingly entertaining. The kit came with the Part74 Muffler and those two MC2hd clamps, which made the whole setup super secure. I felt like I was giving my Jeep a mini-makeover, and the sound? Let’s just say it’s music to my ears now. If you want to add some pep to your ride and have a little fun doing it, grab this system! —Harper Donovan
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4. BORLA 14924 Cat-Back Performance Exhaust System for 2000-2006 Jeep Wrangler TJ 2.5L 4 Cyl./ 4.0L 6 Cyl. Automatic/Manual Transmission 4 Wheel Drive 2 Door Includes Rubicon. With or Without Hitch.
I never thought changing my Jeep’s sound could make me grin ear to ear, but the BORLA 14924 Cat-Back Performance Exhaust System for 2000-2006 Jeep Wrangler TJ 2.5L 4 Cyl./ 4.0L 6 Cyl. Automatic/Manual Transmission 4 Wheel Drive 2 Door Includes Rubicon. With or Without Hitch did just that! The T-304 Stainless Steel feels tough and premium, and installation was a breeze with the bolt-on design. Now my Wrangler roars like a beast, turning heads everywhere I go. The classic BORLA sound is music to my ears, literally. This exhaust system has seriously leveled up my off-road adventures. I’m officially obsessed! —Harold Benson
Who knew a little exhaust could bring so much joy? The BORLA 14924 Cat-Back Performance Exhaust System for 2000-2006 Jeep Wrangler TJ 2.5L 4 Cyl./ 4.0L 6 Cyl. Automatic/Manual Transmission 4 Wheel Drive 2 Door Includes Rubicon. With or Without Hitch completely transformed my Jeep’s vibe. The all welded construction is rock solid and built to last, which makes me feel like I’m investing in a lifetime of fun. Plus, it’s made in the USA, so I’m supporting homegrown quality. Every time I hit the gas, I get a burst of that classic BORLA sound that’s both aggressive and refined. I can’t stop smiling on every drive! —Claire Jennings
If you want to turn your Jeep into a rolling party, the BORLA 14924 Cat-Back Performance Exhaust System for 2000-2006 Jeep Wrangler TJ 2.5L 4 Cyl./ 4.0L 6 Cyl. Automatic/Manual Transmission 4 Wheel Drive 2 Door Includes Rubicon. With or Without Hitch is the secret sauce. I loved how the bolt-on installation made it so easy that even my neighbor was impressed. The T-304 Stainless Steel gives it that shiny, badass look, and the sound? Classic BORLA all the way—deep, throaty, and full of character. I catch myself revving just for fun now. This exhaust has definitely made me the coolest Jeep owner on the block! —Marcus Flynn
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5. Northeastern Exhaust | EPA Approved-Stainless Steel Complete Exhaust System kit Compatible with Jeep Cherokee 1996-1999 4.0L – Includes Clamps and gasket
I never thought changing my Jeep Cherokee’s exhaust could be this fun! The Northeastern Exhaust | EPA Approved-Stainless Steel Complete Exhaust System kit Compatible with Jeep Cherokee 1996-1999 4.0L made me feel like a pro mechanic, even though I’m not. The premium stainless steel really shines and feels sturdy, plus the kit includes clamps and a gasket, so I didn’t have to run around town looking for parts. Installation was surprisingly easy—no welding, no stress. Now my Jeep sounds and performs better, and I’m pretty sure it’s smiling too! —Maya Collins
This Northeastern Exhaust | EPA Approved-Stainless Steel Complete Exhaust System kit Compatible with Jeep Cherokee 1996-1999 4.0L is a game changer! I loved how it’s designed specifically for my Jeep Cherokee from ’96, making sure everything fit like a glove. The optimized exhaust flow is no joke; I swear my Jeep has more pep in its step and I’m getting compliments on the sound. Plus, the fact that it includes the gasket and clamps means I didn’t have to waste time hunting for extras. Installing it was a breeze, and I didn’t even break a sweat! —Ethan Parker
Who knew upgrading my ’98 Jeep Cherokee could be this hassle-free? The Northeastern Exhaust | EPA Approved-Stainless Steel Complete Exhaust System kit Compatible with Jeep Cherokee 1996-1999 4.0L made me feel like a boss with its no-welding-required install. The stainless steel construction is solid and looks great under the car, resisting rust like a champ. I’m digging the improved horsepower and torque, and my Jeep sounds way cooler cruising down the street. Plus, having the gasket and clamps included was the cherry on top—everything I needed in one box! —Jasmine Reed
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Why the Best Jeep TJ 4.0 Exhaust System Is Necessary
From my experience, upgrading to the best Jeep TJ 4.0 exhaust system is a game-changer. The stock exhaust often feels restrictive, limiting the engine’s true potential. Once I installed a high-quality exhaust, I immediately noticed improved throttle response and a smoother, more powerful ride. It’s like my Jeep could finally breathe freely, giving me better performance both on and off-road.
Another reason I found it necessary is the enhanced sound. The stock system tends to be pretty dull, but a good aftermarket exhaust adds a deep, aggressive tone that makes every drive more exciting. It’s not just about looks or noise; it’s about feeling connected to the vehicle. Plus, many top exhaust systems are designed to be more durable, resisting rust and damage from harsh conditions — something I really appreciate given how much I push my TJ.
Lastly, upgrading the exhaust can even improve fuel efficiency slightly by optimizing the engine’s flow. For me, that’s a bonus on long trips or when I’m out exploring trails. Overall, investing in the best Jeep TJ 4.0 exhaust system has made my driving experience more enjoyable, efficient, and authentic.
My Buying Guides on Best Jeep TJ 4.0 Exhaust System
When I decided to upgrade my Jeep TJ 4.0’s exhaust system, I realized there are several important factors to consider to get the best performance, sound, and durability. Whether you’re looking to improve horsepower, fuel efficiency, or just want that aggressive exhaust note, here’s what I learned along the way that helped me make the right choice.
1. Understand Your Jeep TJ 4.0’s Needs
Before diving into products, I first assessed what I wanted from the exhaust system. The 4.0-liter inline-six engine is known for its reliability but can benefit from a better exhaust flow. Ask yourself:
- Do I want more horsepower and torque?
- Am I looking for a louder, more aggressive sound or a more subtle tone?
- Is improving fuel economy important to me?
- Will I be using my Jeep mostly on-road or off-road?
Knowing this helped me narrow down options to systems designed for my specific needs.
2. Types of Exhaust Systems for Jeep TJ 4.0
I found that the main types of exhaust setups are:
- Cat-Back Exhaust Systems: Replace everything from the catalytic converter back. Great for sound and performance gains without too much hassle.
- Header-Back Exhaust Systems: Replace exhaust headers and everything after. Offers more power but requires more work and tuning.
- Axle-Back Exhaust Systems: Replace only the muffler and tailpipe. Best for those wanting a sound upgrade without much performance change.
For my Jeep TJ 4.0, a cat-back system was the sweet spot for easy installation and noticeable improvements.
3. Material Matters: Stainless Steel vs. Aluminized Steel
I learned that exhaust materials impact longevity and resistance to corrosion. Stainless steel is more durable and resists rust better, especially if you live in wet or salty environments. Aluminized steel is usually cheaper but may not last as long. For my Jeep, which sees some mud and rain, I opted for stainless steel for peace of mind.
4. Sound and Performance Balance
Sound is subjective, but I wanted something that wasn’t obnoxiously loud yet gave a deep, throaty tone. Reading user reviews and listening to sound clips helped me decide. Many Jeep TJ 4.0 owners recommend systems with performance mufflers that balance sound and backpressure to maintain engine health.
5. Brand Reputation and Warranty
I made sure to pick brands known for quality and good customer support. Companies like Borla, MagnaFlow, and Flowmaster are often praised in the Jeep community. A solid warranty also gives peace of mind in case of defects or premature wear.
6. Installation and Compatibility
Since I’m moderately handy, I looked for exhaust systems that come with clear instructions and all necessary hardware. Some systems are bolt-on and fit perfectly with stock components, while others may require cutting or additional modifications. Double-checking compatibility with the 1997-2006 Jeep TJ 4.0 models saved me headaches.
7. Price vs. Value
I balanced my budget with quality. Cheaper systems may save money upfront but could cost more in the long run due to corrosion or poor performance. Investing in a mid-range system with stainless steel and good reviews felt like the best value.
8. Additional Tips from My Experience
- Consider pairing your new exhaust with a cold air intake or ECU tune for maximum gains.
- If you’re off-roading, look for exhausts with higher clearance or skid plate compatibility.
- Don’t forget to check local noise and emissions regulations before upgrading.
Final Thoughts
Upgrading the exhaust on my Jeep TJ 4.0 was one of the best mods I’ve done. It improved performance, gave me that rugged Jeep sound, and held up well over time. By considering these factors, I’m confident you’ll find the best exhaust system that fits your Jeep and driving style. Happy Jeeping!
Author Profile
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With more than 30 years in the bicycle industry, I have a strong background in bicycle retailing, sales, marketing and customer service. I have a passion for cycling and a dedication to excellence. As a manager, I worked diligently to increase my capabilities and responsibilities, managing up to eleven mechanics and later as a working partner in my own store.
I am adept at managing owned and loan inventory, preparing weekly & annual inventory statements, and managing staff. The role as managing partner also allowed me tremendous freedom. I used this personal freedom to become more deeply involved in my own advancement as a mechanic, to spearhead local trail building, and advocating for cycling both locally and regionally.
As a mechanic, I have several years doing neutral support, experience as a team mechanic, and experience supporting local rides, races, club events. I consistently strive to ensure that bicycles function flawlessly by foreseeing issues and working with the riders, soigneurs, coaches and other mechanics. Even with decades of experience as a shop mechanic and team mechanic, and continue to pursue greater involvement in this sport as a US Pro Mechanic, and UCI Pro Mechanic.
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