Changing out exhaust on m38. Help!

joebuck · Post by **joebuck** » Sat May 20, 2017 2:46 pm

Hey guys, I bought anew exhaust from kaiser to change our old one. Been under chassis all morning. This thing is a bear for me. Anyone got a diagram for a 52 exhaust? I am confused how the muffler is mounted in the back. Thanks for any help

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4x4M38 · Post by **4x4M38** » Sat May 20, 2017 5:19 pm

Joe,
Start here:

http://www.willysmjeeps.com/v2/modules. ... 38+exhaust

Looks like several things are incorrect, including which
way you have the muffler bolted to the flange of the
middle pipe.

Take care,

4x4M38 · Post by **4x4M38** » Sat May 20, 2017 5:24 pm

Also it looks like your rear hanger is either not attached to the crossmember or is in the wrong location.

joebuck · Post by **joebuck** » Sat May 20, 2017 6:03 pm

I am embarrassed to say I have been under this jeep all afternoon trying to make it fit. Thanks for heads up on rotating the muffler. I have been combing the reference material here but can find a picture of rear exhaust showing hanger bar and how it is atrachwd

4x4M38 · Post by **4x4M38** » Sat May 20, 2017 6:55 pm

Click on the link above. There is a diagram from one of the manuals.
The clamp mounts in a hole in the crossmember forward of the axle.

Be sure and download all of the manuals, available here for free,
above and to the left under downloads.

Take care,

Post by **wesk** » Sat May 20, 2017 8:39 pm

here's Ryan millers exhaust exercise with some very good detailed photos:
http://www.willysmjeeps.com/v2/modules. ... pic&t=1010

OKCM38CDN · Post by **OKCM38CDN** » Sat May 20, 2017 8:43 pm

Looking at your photo your muffler needs to rotate counter clockwise 1 hole as it needs to sit flat parallel with the frame, not on its site... Try that...

If that does not fix the problem; your problem is more than likely the Long exhaust pipe, the early ones were bent wrong near the end where the muffler attaches, you will need to heat it up or take it to a muffler shop to have it bent properly.

John B from Midwest had this problem with his units when they first came out... I got one and had to do the heat and bend thing under the jeep.

John has since had his units corrected... I bet Kaiser Willys is still selling some of the older types and that may be your problem...

I hope this helps...

joebuck · Post by **joebuck** » Sun May 21, 2017 8:49 am

thanks guys!!! I definetly had muffler turn wrong and have corrected it. The picture of rebuild helped me tremendously . Makes sense now . Hal , good info too. I Might have one of those !

joebuck · Post by **joebuck** » Sun May 21, 2017 8:54 am

Here is muffler I replaced. Not sure what the rebuilder used for it

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skyjeep50 · Post by **skyjeep50** » Sun May 21, 2017 10:09 am

I had the same problem replacing my M38's exhaust. Bought everything new from the exhaust manifold to the muffler. Surprise - the components didn't fit correctly! The reason - the manufacturer didn't put the bends and flanges in the correct places. And the mounting is not flexible enough, bolts up only one way, to allow the pipe and muffler to rotate into the correct position. Even after returning parts for supposedly better fitting replacements, I was no closer to getting a proper fit. My solution was to take everything to a friendly neighborhood exhaust shop and have the pipe bends tweaked, flanges cut off and rewelded, enough so they fit properly. The guy told me he could form up a new exhaust pipe easier than bend the existing pieces but I wanted to retain the flange bolted system. You can't bend exhaust pipe without the right tools. Cost an extra $100 to make it right and now its perfect!

charliebrowndog · Post by **charliebrowndog** » Sun May 21, 2017 5:52 pm

Same problem here. A couple of weeks ago I spent a half a day trying to cram a Kaiser muffler into my M38. With the correct brackets it would not fit. I ended up cutting out almost 2 inches and it aligned perfectly. I've learned the hard way to buy the correct parts from reputable suppliers.

OKCM38CDN · Post by **OKCM38CDN** » Sun May 21, 2017 9:11 pm

Trip, they sent you an M-38A1 exhaust pipe, it is longer than the M-38 Pipe...

This is problem with these folks, they claim to be experts and do not know parts from one jeep will not fit another...

joebuck · Post by **joebuck** » Mon May 22, 2017 8:47 am

Great Pic Charlie, it all makes sense now why i spent all weekend thinking i was crazy! Heres is what mine looks like now. I guess i have entered a "Bubba" mod. I feel like calling them and asking them WTHeck!

4x4M38 · Post by **4x4M38** » Mon May 22, 2017 9:15 am

Nah,
We just need to get you a pintle hook or at least a rattle can of OD!!!

joebuck · Post by **joebuck** » Mon May 22, 2017 9:25 am

Good Point! my kids wear me out for taking the Hook off to put that hitch haul bracket on. "Its not original Dad!' "Take it off!" but they dont complain when i haul haul their deer out of woods