Tail pipe rusted off - temp fixes?

[Toystory2]

After hearing some rattling and clanking underneath, I discovered that my exhaust pipe has rusted out from the rear flange behind the muffler. What is the best way to temporarily fix this until I can get it into a shop?

Would exhaust tape be a decent solution for now?

 

[Syr4RinNC]

On closer inspection yours is a different place than mine, but should still work


Ive found the best solution is take a wire brush and clean it up best you can.

The go to advance auto, autozone, o'reillys etc and in their exhaust repair aisle they should have these pipe connectors. I think you want one thats 2 1/4 outer diameter to 2'' inner diameter, but measure best you can. its like $3-4 for that pipe. and get an exhaust clamp. Clamp it to the hanging pipe and then try to twist and wedge that pipe as good as you can inside the muffler.

I found that loctite seems to work best to support it.

In my experience, the exhaust tape, exhaust glue, even JB weld gets too hot on that muffler and flakes off after a few weeks.

I have had mine that way for over 2 years now. Every now and then I have to re-wedge it or take a hammer and try to get it in, but its been staying well so hopefully the metals are starting to meld/ fuse

 

[rwh963]

just rip that pipe section off! i recently installed new oe y-pipe back pipes (see my thread on it). my resonator pipe broke off as well a while ago. i drove it like that for a while. the muffler pipe/y-pipe joint had been leaking for a while. last spring, i grabbed a 2020 4runner cat-back take-off for $50! did the replacement myself (new gaskets/hardware). fit great (tip: drop the spare!). the 2020 is a little different in that it doesn't have the resonator bulge. toyota wanted $1600 to do this job!

*this does not apply to the v8.

 

[Hunter61]

Mine rusted off just like yours did. I tried the exaust tape fix and it lasted about 3 city blocks before it came loose again & started banging around.
No temporary fix is going to last very long. Just completely remove it and get a new one, they're not that expensive. I bought this one for my '04 V8 and it only took 2 days to arrive and an hour to install.

Amazon.com: Walker Exhaust 54617 Exhaust Tail Pipe : Automotive

 

[rwh963]

that joint looks bad as well. not sure what the joint looks like one forward (spring loaded). btw, i've tried the "aluminized" walker stuff. lasts about 18 months, then dies. if you are keeping your vehicle longer, look get an OE take off genuine toyota stainless steel. lasts much longer.

 

[Toystory2]

On closer inspection yours is a different place than mine, but should still work


Ive found the best solution is take a wire brush and clean it up best you can.

The go to advance auto, autozone, o'reillys etc and in their exhaust repair aisle they should have these pipe connectors. I think you want one thats 2 1/4 outer diameter to 2'' inner diameter, but measure best you can. its like $3-4 for that pipe. and get an exhaust clamp. Clamp it to the hanging pipe and then try to twist and wedge that pipe as good as you can inside the muffler.

I found that loctite seems to work best to support it.

In my experience, the exhaust tape, exhaust glue, even JB weld gets too hot on that muffler and flakes off after a few weeks.

I have had mine that way for over 2 years now. Every now and then I have to re-wedge it or take a hammer and try to get it in, but its been staying well so hopefully the metals are starting to meld/ fuse

Thanks I appreciate the tip. Sounds like that would buy me some time for sure.

 

[Toystory2]

just rip that pipe section off! i recently installed new oe y-pipe back pipes (see my thread on it). my resonator pipe broke off as well a while ago. i drove it like that for a while. the muffler pipe/y-pipe joint had been leaking for a while. last spring, i grabbed a 2020 4runner cat-back take-off for $50! did the replacement myself (new gaskets/hardware). fit great (tip: drop the spare!). the 2020 is a little different in that it doesn't have the resonator bulge. toyota wanted $1600 to do this job!

*this does not apply to the v8.

Thank you! You’re giving me some good ideas to go on. I’ll check out your thread. Maybe an opportunity to make it even better if there’s no welding involved.

 

[Toystory2]

Mine rusted off just like yours did. I tried the exaust tape fix and it lasted about 3 city blocks before it came loose again & started banging around.
No temporary fix is going to last very long. Just completely remove it and get a new one, they're not that expensive. I bought this one for my '04 V8 and it only took 2 days to arrive and an hour to install.

Amazon.com: Walker Exhaust 54617 Exhaust Tail Pipe : Automotive

Seems straightforward. My only issue would be fixing the pipe from the flange going forward to the muffler. I supposed I could rig some type of connector from the broken side of the muffler pipe to the new tailpipe.

 

[Syr4RinNC]

My only concern about doing that at home is you’d need a heavy duty saw to cut through and remove things or it looks like youd have to go pretty far forward to find a piece you can cleanly unbolt

 

[Toystory2]

I really appreciate all the insight. I was thinking I could DIY replace the tailpipe, but I’m concerned about the pipe coming from the muffler to the tailpipe since it’s broken off into the tailpipe and will be shorter. Is there a way to fix this without having to replace the muffler too? Maybe by some type of exhaust connector pipe? If not,I’ll probably just replace the muffler too; well the whole thing going up to the cat that is. Doesn’t look too difficult.

 

[Toystory2]

that joint looks bad as well. not sure what the joint looks like one forward (spring loaded). btw, i've tried the "aluminized" walker stuff. lasts about 18 months, then dies. if you are keeping your vehicle longer, look get an OE take off genuine toyota stainless steel. lasts much longer.

The joint looks gnarly too connecting to the cat. Would both sides have to be replaced in this case?

 

[MikeinNH67]

The joint looks gnarly too connecting to the cat. Would both sides have to be replaced in this case?

Yikes, someone tightened those up too much and I think used normal nuts and bolts. I believe mine has springs and bolts that are made to only tighten up to a certain point. Pretty sure there's a big donut gasket in that spot so no need to tighten until the flanges bend like someone did there, just use the correct fasteners.

As for the other pipe issue, you may buy yourself some time by finding a pipe that fits tightly inside both of the pipes (auto parts store, measure the inside diameter) and just clamp/wire in place. That should send most of the exhaust out the back but is still temporary. Muffler tape and such doesn't last where there is pipe movement.

 

[Toystory2]

Yikes, someone tightened those up too much and I think used normal nuts and bolts. I believe mine has springs and bolts that are made to only tighten up to a certain point. Pretty sure there's a big donut gasket in that spot so no need to tighten until the flanges bend like someone did there, just use the correct fasteners.

As for the other pipe issue, you may buy yourself some time by finding a pipe that fits tightly inside both of the pipes (auto parts store, measure the inside diameter) and just clamp/wire in place. That should send most of the exhaust out the back but is still temporary. Muffler tape and such doesn't last where there is pipe movement.

Hmm that makes sense as to why it’s warped. I was wondering why it didn’t have the spring loaded bolts. I’ve decided to install a new cat back system. Gibson Elite. Doesn’t look to terrible to install. Getting the old one out is a different story…

 

[4r-4ever]

definitely the way to go, replace the old catback. when i replaced mine with walker, i had to clean the walker catback and painted it black using a high temp paint. looks great and it seems the paint is doing its job from rusting. just cut the old one to remove it. very easy if you have the right blade.

Hmm that makes sense as to why it’s warped. I was wondering why it didn’t have the spring loaded bolts. I’ve decided to install a new cat back system. Gibson Elite. Doesn’t look to terrible to install. Getting the old one out is a different story…

 

[rwh963]

The joint looks gnarly too connecting to the cat. Would both sides have to be replaced in this case?

should straighten those flange ears before new system. is it going be stainless? you can just sawz-all those bolts in between the flanges.

 

[Toystory2]

should straighten those flange ears before new system. is it going be stainless? you can just sawz-all those bolts in between the flanges.

Yep it is stainless. Just came in and it didn’t come with new bolts for the flanges. Local parts stores don’t seem to have the replacement spring bolts.

 

[rwh963]

i bought my gaskets and hardware at napa.