The LongRanger is getting lippy - it's talking back!! I replaced the flange on the back of the cat for the second time (at 394000Km) with a split flange because the exhaust disconnected, and it is still talking. Ends up it has a leak on the front corner of the back cat - I hope to be able to weld a patch on it to save myself about $1500 for a new cat. However the factory muffler is also perforated. The rest of the pipes appear to still be pretty good, but I've been looking at replacing the "cat back" with a new stainless system. I KNOW I can have one custom made - did it in the past on my AeroScare,
There are systems made listed for 1998 to 2011. What is different on them from a 1996? Anything that would prevent installing on a 1996 4.0 longbox single cab?? (7 foot box 114 inch wheelbase) I know the '98 is a few inches longer than the '96 because of the larger cab but would it be as simple as removing a couple inches of pipe from the intermediate? A 2 1/2 inch system with a nice chrome tip and a mellow performance tone would be nice - and likely less work than trying to put an aftermarket muffler on the original pipes, and fit better than a bodged up muffler shop system.
I had a lean code (again) too, and the culprit was the same as it was about 10 years ago - the hose from the throttle body to the evap valve. I was afraid it MIGHT be from the exhaust leak. Got it all repaired , turned off the CEL and took it for a drive and the CEL came back on. DARN!!!! Checked the code - I had disconnected the IAT sensor and forgot to plug it back in. PHEWW!!!!