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Old 07-29-2022, 12:26 AM #1
Dragon_EX Dragon_EX is offline
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Looking to replace the entire exhaust system

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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Old 07-29-2022, 03:33 AM #2
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Quote:
Originally Posted by Dragon_EX View Post
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.
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.
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Last edited by Buckaroo; 07-29-2022 at 03:44 AM.
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Old 07-31-2022, 11:24 AM #3
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Quote:
Originally Posted by Dragon_EX View Post
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.
I installed a URD y-pipe on my 2011 which I'm loving and plan on doing the whole exhaust on my 3rd gen soon like you but URD only has headers on their site for 3rd gen. It took me a little while to figure out but can tell you that loosening the exhaust manifold nuts slightly made the whole thing much easier. Then tightened them after everything lined up.

I wouldnt worry about gaskets much Fel-pro is fine. That URD pipe needed different ones because flanges are billet aluminum. The Toyota ones are much more expensive anyway. Personally I'd want to keep all the piping one brand, find a whole kit. Replace the muffler tension springs if they have compressed.
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Old 08-15-2022, 10:17 PM #4
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I've been working on the exhaust the past couple of days and unfortunately things have not gone smoothly for me. One of the threaded studs that hold up the first cat just sheared off! So that has set me back an entire week while I wait for the right tools to get here so I can drill it out and re-tap the hole.

I should explain the preparation that I had to do in case anyone in the future would like to do the same thing, that is replace an entire exhaust without ever having done one before... The first thing I did was paint the welds on the muffler with high-temp paint as was suggested by Buckaroo. The tail pipe actually came from the factory with the weld on the flange already painted, so since I had an entire can of this paint I decided to paint all the welds on all the pieces, after masking off the inlets, outlets, and O2 sensor holes. On my old exhaust the flange welds is actually where all of the leaks were. Speaking of the O2 sensors, in both of the catalytic converters the threads in the hole and on the studs had some weld splatter stuck in them which would have made it impossible to install the sensors. Fortunately, specific O2 sensor thread chasers are available and inexpensive and cleaned the holes right up. As for the studs I used a crappy nut I had laying around and used that to clean the thread, which might not have been the best idea but it worked out for me (in my case, the front O2 sensor is attached via the studs while the rear sensor is screwed directly into the hole). After that it was all ready to be put on. Well, it would be if that bolt didn't break.
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Old 08-16-2022, 11:28 PM #5
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Quote:
Originally Posted by repo View Post
I installed a URD y-pipe on my 2011 which I'm loving and plan on doing the whole exhaust on my 3rd gen soon like you but URD only has headers on their site for 3rd gen. It took me a little while to figure out but can tell you that loosening the exhaust manifold nuts slightly made the whole thing much easier. Then tightened them after everything lined up.

.
I've been looking at my aging crossover pipe, and that Y pipe you are talking about was surely to eliminate that ?

With what manifold and exhaust did you couple that?
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