Rusted out tailpipe connection?

[BenK]

My 4Runner was making an inconsistent rattle at idle and only when in drive. I did a search and found some cases where the problem was a loose heat shield. So today after work I got under the truck to look for the culprit. Much to my surprise, I found the problem was that the flanged connection just after the muffler was so rusted out that I was able to simply pull the entire tailpipe section out. The studs and bolts are almost gone and the rattling was the two flanges hitting each other.

As you can see from the picture, the rest of the underside is really clean. The only major rust is at the connection. Anyone else have this problem? Can I just take the tailpipe to a muffler shop and have them recreate it, cut off the rusted flange, and weld a new one in place?

 

[BenK]

Bump.

Anyone?

 

[rajuncajun]

You can...but it's hokey. It's thin metal and thus hard to weld. It's much more worth your while to go new.
You're better off getting new stuff bent - or buying new. If you're on a budget check scrap yards for a cat back exhaust - but they are hard to find mostly due to the problem you are having.
Mine did the same thing.

 

[theoaker]

I was under my 4runner.looking for.a.gas flow issue and found the exact tail pipe problem.

 

[slomatt]

Coincidentally I just noticed I have the same problem as well. I was under the truck doing an inspection and noticed water was coming out of that joint (engine was cold), so I must have a leak there somewhere.

- Matt

 

[BlackCat914]

Have an exhaust shop cut out the flange and weld in a piece of pipe. You don't really need a flange there, unless you plan on taking it off a lot. I do those types of repairs at work all the time.

 

[OTB]

Or go to ebay and get a full cat back system for $150 shipped.

 

[noxor]

bringing back an old one!

what did anyone with this problem do to fix it? I have the same issue in 2 places, both at the flanges only.