2003 V8 Full Exhaust System

[TRDCal]

Well I got my truck back late last week but is was a busy weekend so I didn't get a chance to update here.

For starters, the headers are not fully completed yet....I can feel everyone roll their eyes LOL. He first tried to make the headers from 1 3/4" pipe and they were too big so hes going to try 1 1/2". If he can't come up with anything them I going to have him replicate the stock manifold which should be simple enough and cheaper.

SO currently it has just the 2 1/4" dual pipes, muffler and third cat delete. I was worried about lossing low end torque but there's none of that. Its got a real thoaty sound and definitely brings some life into the 2UZFE. I don't have pictures or 0-60times but that will all come, I've just been too busy lately.

 

[Jay Nice]

If he can't come up with anything them I going to have him replicate the stock manifold which should be simple enough and cheaper.

I wish you owned an 06, I'd duplicate the order for some stock manifolds if it were a possibility. However, I do hope he can make these headers for you in the end. Can't wait to see some pics of the tail end with the dual setup!

Is it worth while to start talking with some of my local exhuast shops in order to fab up some stock mainfold replicas? Would it be cheaper & better quality by taking this route? I guess I would also have to sacrifice not having the 4R for the time being which I don't think is an option for me. This is painful having this issue with these mainfolds... :ybrick:

 

[ChaosStarter]

Well I got my truck back late last week but is was a busy weekend so I didn't get a chance to update here.

For starters, the headers are not fully completed yet....I can feel everyone roll their eyes LOL. He first tried to make the headers from 1 3/4" pipe and they were too big so hes going to try 1 1/2". If he can't come up with anything them I going to have him replicate the stock manifold which should be simple enough and cheaper.

SO currently it has just the 2 1/4" dual pipes, muffler and third cat delete. I was worried about lossing low end torque but there's none of that. Its got a real thoaty sound and definitely brings some life into the 2UZFE. I don't have pictures or 0-60times but that will all come, I've just been too busy lately.

I'm surprised you went with the dual 2.25". I think it's fine for the V6's but I'd try for the 2.5" system........ but I guess if you are running true duals, the 2.25" could be enough, whereas a y-pipe system should definately get 2.5" each side into the y-pipe, and possible 3" back.

 

[TRDCal]

Is it worth while to start talking with some of my local exhuast shops in order to fab up some stock mainfold replicas? Would it be cheaper & better quality by taking this route? I guess I would also have to sacrifice not having the 4R for the time being which I don't think is an option for me. This is painful having this issue with these mainfolds... :ybrick:

From my experience I'm going to say yes. This is the cheaper and better route when compared to OEM. A lot of it will depend on your local exhaust shop as far as quailty, materials and warranty. As far as being without your truck...it definitely sucks but there's no way around that however your might find a shop that can do it more quickly that mine.

I'm surprised you went with the dual 2.25". I think it's fine for the V6's but I'd try for the 2.5" system........ but I guess if you are running true duals, the 2.25" could be enough, whereas a y-pipe system should definately get 2.5" each side into the y-pipe, and possible 3" back.

One of this biggest concerns I had was getting a pipe too big and loosing low end torque. I always see these Honda Civics around with 3" catback exhaust...famous for making lots of noise and thats about it. So we went with 2 1/4" which isn't that small when you consider its only running 4 cylinders. Plus there small cylinders at that. Were not talking about a 6.0L GM here, yah know, its a rather small V8 so the exhaust diameter is fitting. Thats not to say its looks too small either, i'd say its just perfect

 

[ChaosStarter]

One of this biggest concerns I had was getting a pipe too big and loosing low end torque. I always see these Honda Civics around with 3" catback exhaust...famous for making lots of noise and thats about it. So we went with 2 1/4" which isn't that small when you consider its only running 4 cylinders. Plus there small cylinders at that. Were not talking about a 6.0L GM here, yah know, its a rather small V8 so the exhaust diameter is fitting. Thats not to say its looks too small either, i'd say its just perfect

I understand your reasoning, but for the last two decades the 4.6L Mustang guys upgrade to true dual 2.5" exhaust without any real loss in low end torque, and the motor size is a hair smaller. Now, those SOHC motors tend to make a little more torque than an equivalent DOHC motor, but nonetheless, I would think there wouldn't be a huge difference. If a 4.0L V6 'upgrade' is 2.25", I think the 2.5" (especially one that isn't a true dual system) would be perfect.

I need to learn how to weld. I'd like to try this theory out. lol.

 

[TRDCal]

Oops...I thought I replied to this thread last week.

Anywho, as for the exhaust diameter I'm not sure why he went with 2 1/4" . I don't know anything about exhaust theory but the guy who designed my system has been doing exhausts since the 90's and he's done a couple Tundra's so I trust his decisions. One thing I do know tho, this system is way more free flowing than the stock system and the customer is happy so it's a win win.

Just to update the thread, I brought my truck back to the shop last week and its suppose to be done on Aug. 24th eventhough I won't have an official update until 29th ish. Stay patient guys, I do have a picture of one of the mocked up headers but I don't want to jinx anything and post it because sure enough then it won't fit.

 

[TRDCal]

Just an update.

Truck still isn't finished, it's getting to be a bit of a joke but he's still got good excuses so I'm going along with it. Last week, the headers were getting plated with some sort of thermal coating to eliminate the need for heat shields. Unfortunately that took longer than expected and I needed my truck so I picked it up before he had time to finish. Anyways, I will keep y'all posted.

 

[TRDCal]

Well its been 11 months in the making but they're finally done and I couldn't be happier! They sound and look great and best of all...NO MORE TICK! Plus the whole system from the engine to the tail pipe cost what I was going to have to pay for just Toyota manifolds not installed





The original design had to be modified abit to clear the steering shaft and the Oil and Tranny dipsticks had to be moved slightly but other than that they fix like a glove. I had him reuse my stock cats to keep costs down.

As expected it through two codes, P0037/P0057 Heater Control Circuit Low (Bank 1, Sensor 2/Bank 2 Sensor 2). Not the code I expected to get from moving the cats so I'm going to look into it abit but most likely just get a couple URD O2 sims.

EDIT: Haven't gotten a chance to get a updated 0-60 time yet since its be raining but I will post the results when I do.

 

[rebelbowtie]

Wow you're a patient man! 2.25" is plenty on a stock v8 with true duals IMO, I saw you referenced the GM 6.0 and it's factory exhaust is too large for it; that's why it has several reducers and an large muffler that turns into a single pipe before termination. They share the same exhaust with the 8.1 big block!!!

 

[kpatler]

Think they'd be willing to reproduce these for someone? I've got an '05 with "the tick" and would love a custom set that still retains stock Cats.

 

[TRDCal]

Think they'd be willing to reproduce these for someone? I've got an '05 with "the tick" and would love a custom set that still retains stock Cats.

I'm sure they would. Unfortunately tho 05-09 V8s have VVTi so they wouldn't be the same as mine.

 

[WXman]

I'm interested to see if you pull this off without sending the ECU's emissions checks into orbit and lighting up the dash like a Christmas tree.

 

[TRDCal]

I'm interested to see if you pull this off without sending the ECU's emissions checks into orbit and lighting up the dash like a Christmas tree.

Little update on that situation...I crawled under my truck to meter the sensors and found that both rear sensors had been left unplugged. So I plugged them back in and am interested to what happens. It will get rid of the current codes but I could see it throwing a P0420 code now that it'll get feedback from the sensor. I should know it a couple days.

Since my truck is in my shop now in pieces! The TICK came back when under load so I took the headers off and looks like they reused the old beaten up gaskets so I'm going to replace with new. If you want something done right, you got to do it yourself!

The shop makes a great product, but the installation/customer service is below par. It's a shame because now I'll never go back, fool me once shame on you, fool me twice shame on me.

 

[LOSTR4]

Hi All,

I thought I'd post this here. I've finally had enough of my ticking exhaust manifolds, so I went to a custom exhaust shop (Stebro LTD) to see what they could do.

The guy I spoke to seemed keen on this project, he put a system on his 4.7 Tundra so it won't be their first 2uz.

Price is not going to be cheap! $1600 for custom header-manifolds + 900 for a single cat-back system or $1200 for a dual cat-back system. Keep in mind it's made from stainless steel and has a lifetime warranty. I thinking its well worth it since the dealer wants $2500 just for new manifolds and I'd have to install them.

If all goes well, I will bring my truck in mon. and they should be done by thurs. I'll post pics!

Stebro is a great exhaust system! I have it on my Audi and they're often used on many German cars. Looking forward to hearing it!

 

[TRDCal]

Stebro is a great exhaust system!

Yah the quality of the headers is top notch, couldn't be happier there. The flange is like 3/8" thick stainless, she'll long outlast my 4runner.

As far as the ticking issue, they say they did use new gaskets so I guess the only possibility is that the header loosened off and the escaping exhaust damaged it. Oh well, I going to put new gaskets and see.

 

[LOSTR4]

I bet you'll just have to re-tighten them...I had the same issue with mine...I'm not sure why it happened, but after it was re-tightened, the ticking subsided. Good luck and look forward to hearing a sound clip when done!

 

[TRDCal]

Yah I got the new gaskets installed today and it sounds great. No ticking, I'll re-torque the bolts after a driving abit. Not sure my digital camera will record the sound good but I'll give it a shot.

 

[TRDCal]

I'm interested to see if you pull this off without sending the ECU's emissions checks into orbit and lighting up the dash like a Christmas tree.

No dice...I plugged the sensors back it but now it's throwing a P0420 code, only on bank 1 tho interestingly enough.

 

[WXman]

So what are you going to do? You can't drive it like that right? The MPGs would suck and the engine will run lean and possibly cause damage.

 

[TRDCal]

Just want to give an update and finalize this thread once and for all. After resetting the code a couple times, I'm pleased to say that it hasn't returned! It's been about 8 months of spirited and calm driving in temps from +30 to -30 Celcius and it hasn't hiccuped. I can't describe how great it is to start the truck up and not hear ticking noise. Not including lift/tire its by far the best mod I've done to my truck.

The MPGs would suck and the engine will run lean and possibly cause damage.

FYI, the fwd 02 sensors are the ones that monitor mixture, the aft ones simply monitor the efficiency of your cats. The big worry for me was passing emissions test which as long as no codes are being thrown, it will not be an issue.