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Originally Posted by Dragon_EX
Currently in my 2002 my exhaust is filled with leaks and covered with rust, and both cats are most definitely shot which is evident by the fact I've been driving around with a p0420 code for years now. Bottom line is everything needs to be replaced, from the first cat to the tail pipe. The pipes are just so mangled that replacing everything seems like the best option. The dealer quoted me over $3000 to get that done... So decided to just do it myself. I've been on Rock Auto picking out parts and pricing it out but started having a lot of questions that I can't find the answer to. I only recently started doing this kind of work myself and want to make sure I get everything right. Firstly, does it matter what brand of gasket goes with what brand of part? I've only found this diagram for part numbers from Walker, but I don't know if it matters that everything needs to be the same brand. After that I just need to know what bolts and nuts to buy because none of the parts come with them and they also don't say what size is recommended.
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You can use any brand gasket - just needs to be the right diameter. Start with the recommended Walker ones from Rockauto (low cost). If you find that you need additional gaskets, you can go to autoparts store locally to source. May find you need thicker gaskets or perhaps two in a particular joint if you have a leak. Regarding fasteners, just go to the local hardware store once you get your parts and can see what you need. Get them long enough and use washers on both ends if they will fit. Larger diameter is better and don't need SS - galvanized is fine. FYI...when removing old exhaust, you have to get the bolts out on the manifold connection but after that you can just cut everything off with a sawzall or torch. If you haven't replaced O2 sensors, you may want to do that as well. Careful sourcing the correct ones to get the right pig tail length - recommend Denso.
Also, the Walker lifetime warranty parts will rust out - last maybe 2-4 years in the mid-west. Clean the welds up on the pipe connections with a wire brush and paint them with high temp paint before installation. That is the first place they rust out.