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  3. 49-46223

aFe Power 49-46223 Installation guide

  • Hello! I've reviewed the provided installation instructions for the aFe Exhaust System TJ Hi-Tuck and Cat-Back Exhaust 409 SS 49-46223 designed for the Jeep Wrangler TJ. This document covers the step-by-step installation process, from removing the old exhaust to securing the new components. It also provides important notes on heat protection and the need for controller/programmers. Feel free to ask me any questions you have about the installation process or the system itself.
  • What vehicle is this exhaust system designed for?
    What is the recommended procedure before beginning the installation?
    What should be done after the installation is finished?
49-46210 Jeep TJ Hi-Tuck
2.5” Exhaust System
INSTALLATION INSTRUCTIONS
MAKE: Jeep
MODEL: Wrangler TJ
YEAR: 1997-2006
ENGINE: L6-4.0L
WHEELBASE: 93.4"
2.5" Cat-Back Exhaust
49-46223 (409 SS)
Muffler
49-91031
Band Clamp
05-41061
Band Clamp
05-41061
Over Axle/Tailpipe
05-44594
Mid Pipe w/o Flange
05-44593
Step 1: (Read Instructions prior to installation) Remove your stock exhaust from the rear of your truck working your way
forward. Take caution not to damage the factory isolation mounts as they will be reused. It may be helpful to lubricate the
isolation mounts prior to disassembly. It is recommended to not fully tighten the clamps until the entire system has
been installed.
Step 2: For faster installation spread the pieces of the exhaust along side of your vehicle according to the diagram shown.
Step 3: Install the over-axle assembly, utilizing the factory isolation mounts. It may be necessary to remove shock absorber.
Step 4: With 2.5” band clamps install muffler to over-axle assembly. Make sure center inlet on muffler is towards front of
vehicle. Offset outlet should face towards rear of vehicle closer to drive shaft.
Step 5: Select and install mid-pipe with 2.5” band clamp to muffler. Install and tighten bolts at cat side. To adjust for
alignment, tighten all connections and reinstall shock absorber if removed, tighten to factory specs. Your installation is now
complete. It is recommended by aFe to re-tighten all parts after 50-100 miles and continue to check periodically.
NOTES:
• aFe recommends that the tailpipe be at least 1/2”-1” away from any body panels to avoid heat related body damage. Tighten and secure.
• Controller/Programers are required to operate this system. Extra sensor bungs are included and need to be welded in place if your programmer requires sensors.
Caution: Allow time for your vehicle to cool down prior to installation. When working on or under your vehicle proceed with caution. Exhaust systems reach high
temperatures and may cause serious burns. Wear protective safety equipment; eye goggles and gloves to ensure a safe installation. aFe recommends professional
installation on our proaducts.
06-85646
Updated: August 2012
Band Clamp
05-41210
Mid Pipe w/Flange
05-44592
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