DIY Exhaust Muffler Tail Pipe Replacement
- Thread starter 46runner
- Start date
ive been able to weld it back a couple times. lasted about a year each time. this time i just took the tailpipe out and stuck a turn down in the back of the muffler. if i want to keep the stock system i could prolly cut the turn down into a union that fits inside in between the muffler and tailpipe.
if a muffler rusts out in 2 years it was aluminized not SS. walker only makes a SS now, maybe they made a cheaper version before.
since i have at least one cracked manifold i will be doing DT headers in the summer. while im at it i will replace everything from y-pipe to prolly gibson ss cat back with side exit
DT is making new long tube headers and a y-pipe as we speak but wont include cats. i prefer to have clean exhaust and will fab cats onto the shortys with vband clamps so if i have an issue down the road with cats i dont have to unbolt headers
if a muffler rusts out in 2 years it was aluminized not SS. walker only makes a SS now, maybe they made a cheaper version before.
since i have at least one cracked manifold i will be doing DT headers in the summer. while im at it i will replace everything from y-pipe to prolly gibson ss cat back with side exit
DT is making new long tube headers and a y-pipe as we speak but wont include cats. i prefer to have clean exhaust and will fab cats onto the shortys with vband clamps so if i have an issue down the road with cats i dont have to unbolt headers
Berty_K
Member
Exhaust is brand new and all from Walker. Muffler is their SS series. Did some more research. I believe I only need mild grade steel bolts.
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TNFISHRMAN
New member
Do I need a special bolt to connect these two pieces? It’s between the resonator and muffler.
If I don’t, what size bolt did you use?
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Did you ever figure out the bolts to use for the connection between the resonator/tail pipe and muffler
Berty_K
Member
It's just a standard mild steel bolt. M10 or 12- can't remember off the top of my head
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Berty_K
Member
amitchell24
New member
What size bolts did you use to connect the tailpipe to the muffler section?
amitchell24
New member
Sorry just saw the answer
CelticRunner
Member
Finding this thread very useful. Thanks.
Mine rusted out previously where the pipe connected to the muffler (rear side) and had it welded back on. The weld held strong but now the pipe itself is rusted through. Didn’t notice until I heard the rattle at certain RPMs again.
Anyone experience this? Do I need to replace the rest of the tail pipe as well? Or can I just replace the muffler?
I assume I need new bolts since they are thoroughly rusted. Can I reuse the rubber connectors?
Place holder for when I can figure out how to post an image*
Mine rusted out previously where the pipe connected to the muffler (rear side) and had it welded back on. The weld held strong but now the pipe itself is rusted through. Didn’t notice until I heard the rattle at certain RPMs again.
Anyone experience this? Do I need to replace the rest of the tail pipe as well? Or can I just replace the muffler?
I assume I need new bolts since they are thoroughly rusted. Can I reuse the rubber connectors?
Place holder for when I can figure out how to post an image*
For the tailpipe I replaced the one on my '04 sport with this one. It was a perfect fit.
Amazon.com: Walker 54617 Tail Pipe: Automotive
CelticRunner
Member
Here is where the connection went. It’s completely disconnected right at the muffler side of the connecting joint, but the pipe coming out of the rear of the muffler is completely rusted through, vertically along the bottom of the pipe
And another view:
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CelticRunner
Member
Thanks for the reply. I’m having trouble opening the link. Are you saying I need to replace the whole end tailpipe as well?
You could do that but I didn't want to bother with cutting & rewelding. At $60 for a new one the savings would be minimal.
CelticRunner
Member
Thanks. I’ve watched a couple videos and I think I can handle pulling out and attaching/bolting in the new muffler. I’d like to avoid unnecessary work/costs and cutting/welding is way outside of my capabilities.
So other than the muffler and new bolts, do I need any other parts? New rubber connectors? The ones there seem to be in good enough condition.
I’ll probably grab the stainless steel muffler from Walker in a week or so, unless someone opines otherwise.
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AuSeeker
Elite Member
If the rubber hangers are not dry rotted you can reuse them, bend them to see if there's any cracking from dry rotting.
CelticRunner
Member
Thanks! I’ll take a second look at them.
I guess I was a little uneasy about continuing to use the original tail pipe just do to the rust all over the connection piece. I hate what the north east (and the heavily salted roads) does to the underside of these vehicles)
Syr4RinNC
New member
It’s all just pipes - however you can connect them with a pretty good seal will work. Certainly oem design and connections will work.
My muffler rusted through at the exit point. I got an exhaust connector and a bunch of jb weld and it’s held together okay. I need to figure out a better exit because I keep crunching it on trails with a poor departure angle - so side exit or cutting or something
My muffler rusted through at the exit point. I got an exhaust connector and a bunch of jb weld and it’s held together okay. I need to figure out a better exit because I keep crunching it on trails with a poor departure angle - so side exit or cutting or something
46runner
Member
I ordered the "Walker 35138 Exhaust Bolt Kit" from Amazon. Looked it up on Amazon but it did not mention the bolt size.
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