Here's the TL;DR part: What do you guys recommend for a muffler that sounds like OEM/stock and/or quieter? I don't want anything louder than stock.

I need something that runs from right behind the catalytic converter to the part that turns down right after the muffler. And not super expensive. I need to be able to bolt it up myself.

Background below, if you're interested. Feel free to skip.

So... let's start off with some pictures:







Hole is about 6 inches long. Maybe just shorter.

As you can see, I've discovered some frame rust. This is on the rear passenger, by the horizontal arm that runs alongside the rear passenger suspension. (I can't recall the name of the arm at the moment, if someone could remind me, much appreciated) This is the ONLY frame rust I have found (other than some on the rear wheelwell edge), after a close inspection by me and someone else... Most of the other rust is very light, and I even sanded the area around the hole and the shiny steel came to light very quickly, so it is still very solid. The area around the hole is black since I sanded down the nearby area and sprayed on some Rustoleum Rust Converter, as a test, and something to put down before the plate gets welded on.

I have a quote of around $100 to weld a plate over that, IF I can get the muffler off. I've closely examined the bolts on both ends of the muffler, and there is no way on earth I'm gonna get them off with regular tools, or even with something like PBlaster, since this has rusted together, big time. (from right behind the catalytic converter to the other side of the muffler where the pipe turns up). Gonna have the fab shop drill the rusty bolts out at this point, and then I'm hoping to install another muffler in myself, by just bolting things up.

As also evident from the pictures, the muffler isn't doing much (got a lengthwise rip in it, from rust, I think). I figure on replacing the muffler, as to make it future Smog test proof, for if I ever have to register in a required smog state. (yes, I know; my state is awesome. No smog tests, no salt on the roads, and unlimited public lands for off road!)

Here's the TL;DR part: What do you guys recommend for a muffler that sounds like OEM/stock and/or quieter? I don't want anything louder than stock.

THANKS for any help, comments, or feedback you guys can give. Much appreciated!

Well first off I have no idea what brand my muffler is. But I just went to my local muffler shop and asked for an OEM style replacement. It's barely louder than stock (maybe a bit deeper but loud is never a word I'd use to describe it). He charged me 80 bucks for it and the piping (check my thread for a pic of how he piped it).

So if it were me. I'd chop the exhaust after the cat. Get the frame fixed. Then head straight to the muffler shop. He got my muffler and piping done the same day without calling ahead. Maybe took 2 hours.

I hear Walker Quietflow is good. Make sure you get stainless steel or it would rust quickly. I would check out the JBA exhaust. Stainless steel muffler and pipes and all bolt in for ~$350. I hear it isn't loud out all.

Did he weld it on, or bolt something else up?

I'm tempted to take a sawzall through the exhaust pipe, right after my rear O2 sensor (which is just after the cat), and then have something welded up.

For example, there's this: New Muffler Rear Natural 4 Runner 56 in Oval Toyota 4Runner 97 96 2000 99 1997 | eBay

A no name, but I can't tell if it's gonna be louder or quieter. Or I can get a "Walker Quiet" for like $177.

Guess mufflers really don't matter much, just slap one on and go?

Thanks TCMach!

Aluminized? I take it that will rust?

Walker Quiet Flow 3 Muffler 55054 | eBay

I replaced mine with a used OEM muffler. Had rusted out bolts. Use a hammer and hit the bolt head several times to loosen the rust. Worked for me.

If you break a bolt, drill it and take the remaining bolt out by one of those bolt extractor.

ooh, I didn't think of that, to hit it with a hammer. Problem is, on one side, where the pipe goes up (after the muffler), the bolts are so rusted, they don't even have a shape. It's pretty bad. I think I'm gonna get these bolts drilled out.

Thanks nissanh!

After talking a bit with a friend who's good with this stuff, it seems I'll be going with a Walker Quiet Flow.

Walker Exhaust 55054 Muffler Assembly-Quiet-FlowSS : Amazon.com : Automotive

You still haven't done this yet? I thought we talked about this like a month or two ago. lol.

just cut it off and I was going to say put in a walker replacement. kinda funny that the fab shop is willing to drill out some bolts but not slip the ends of a muffler over the stock pipe and weld it together. That's probably a 15 minute job for someone that doesn't weld every day.

but hey, if you can get it unbolted... that works great too.

I remember your thoughts on the other thread. And that was like 2 weeks ago, I've had to push this off until after a big test, so I'm done with that and making this my goal right now.

Probably just gonna either have the muffler cut off and the patch done and then go to a muffler shop and have them do the rest.

Farmerjon, is your 4runner originally from WY?

Nope, unfortunately not. It's a OH truck, up to about a year ago. It was in OH since new, for about 14ish years, is my impression. I'm the 2nd owner.

Probably the only thing I really regret in buying this truck, was buying one with rust. I know SOOO much more than I did a year ago, whether it be in the area of spark plugs or rust or 4Runners in general.

wait only two weeks?

WTF have I been doing??

Yep just welded right to the chopped stock pipe.

And that's what I did haha. Chop it off and take it up there. And my muffler is a little bit smaller than both of the ones you posted and it's still quiet. If you ask for something quiet and OEM sounding any shop worth it's salt will set you up with something your happy with.

Well that makes more sense. I was gonna say, if its been in WY its whole life theres no way there should be that much rust.

And I was the same way. I knew next to nothing about auto work, and even closer to next to nothing about the 3rd gen 4runner, before joining this forum. Now I feel like a semi-moderate-somewhat-intermediate-becoming veteran. The key word being semi-moderate-somewhat-intermediate-becoming

Yeah, my hope is that the rust will drastically slow or stop in this climate here. Problem is if I ever go anywhere else, I'm just gonna get more salt. Big project of the summer is going to be rust-treating. Probably with OSPHO and then some VHT chassis paint. We'll see. I was really happy to find how solid the steel is around that hole, because I would sand for just a few seconds, and it would show the bare steel really quickly.

Yeah, it's amazing how much hanging around these forums and reading stuff teaches things!