Temporary muffler rear pipe fix

Kmvreter

Kmvreter

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Did a search on this and didn't find anything. Thought I would do a write-up just to document it.

Noticed a new metalic "tinny" rattle starting a few days ago. It was rpm related at idle. Thought it might be an exhaust heat shield had come loose again. Finally had a chance to get under and look at it. Nothing obvious until I grabbed the rear exhaust pipe and it broke completely loose at the muffler. It had rusted through and made a clean break. The rest of the pipe is solid. The muffler is intact but is showing signs of age at the seams. I decided to do a temporary fix while I shop around for muffler options.

Here is the break (with the pipe held up with wire.) Over 10 years, 310,000 Km (193K mi.)
 

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Went looking for exhaust adapters that would fit. Best option I could find was a stainless steel 2-1/4" O.D. piece, 5 or 6 inches long, to use as an internal sleeve (Canadian Tire #012-8780-6.)

Here it is dry fit into the end of the pipe. Marked it for depth.
 

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Dry fit into the muffler with a slide fit. Didn't need to cut the length.
 

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Gooped in place with muffler joint seal. Ran the truck a couple of times to warm the muffler and help with the curing. I let it cure solid for over 4 hours before going to the next step.

"New" exit stub on the muffler.
 

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Temporarily shimmed the rear pipe to hold it above the cross member before making the final connection in the next step.
 

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Final connection of the pipe sealed over the stub.
 

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Total cost of under C$20. As usual, a chance to work on the truck: priceless.

Now to find a muffler. I'm not after a different sound.
Stealership wants C$505 + gaskets for stock replacement. Stealers in the US want U$470 (not much different.) I've found it online for U$327 but shipping is an issue. I was quoted under C$300 locally for an aftermerket but I'm not sure about longevity. I'm thinking of going stainless steel.

What is a good, quiet, non-stock replacement and do they come with the pipes as a direct bolt on?
 
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Kmvreter said:
What is a good, quiet, non-stock replacement and do they come with the pipes as a direct bolt on?
Click to expand...

You should be able to get a stock replacement for cheap, but a 24" magnaflow or flowmaster super 70 are around $100-130 + about $50 to be welded in. However, with the amount of rust on your exhaust system so far, i'd suggest having the whole thing inspected and/or replaced.
 
Kmvreter said:
Total cost of under C$20. As usual, a chance to work on the truck: priceless.

Now to find a muffler. I'm not after a different sound.
Stealership wants C$505 + gaskets for stock replecement. Stealers in the US want U$470 (not much different.) I've found it online for U$327 but shipping is an issue. I was quoted under C$300 locally for an aftermerket but I'm not sure about longevity. I'm thinking of going stainless steel.

What is a good, quiet, non-stock replacement and do they come with the pipes as a direct bolt on?
Click to expand...

I went with a Walker Quiet-Flow SS muffler when my stock exhaust rusted through.

http://www.toyota-4runner.org/4th-gen-t4rs/168274-went-walker-quietflow-muffler.html
 
NOVA46 said:
You should be able to get a stock replacement for cheap, but a 24" magnaflow or flowmaster super 70 are around $100-130 + about $50 to be welded in. However, with the amount of rust on your exhaust system so far, i'd suggest having the whole thing inspected and/or replaced.
Click to expand...

The muffler is actually part of the "Exhaust Pipe Assy Center" which includes the welded on front and rear pipe sections (see attached pdf.) These are all more corroded than the actual front section and rear tail pipe. As you suggest, I'm looking to replace the entire center assembly.
 

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Kmvreter said:
The muffler is actually part of the "Exhaust Pipe Assy Center" which includes the welded on front and rear pipe sections (see attached pdf.) These are all more corroded than the actual front section and rear tail pipe. As you suggest, I'm looking to replace the entire center assembly.
Click to expand...

Bite the bullet

Why not at this point?
 
Kmvreter said:
Thanks Bossman. Just what I was looking for. Mind me asking where you got it (chain store or independent shop), how much it cost and can you verify the part as #56177?
Click to expand...

I got the muffler/extension pipe and tail pipe at an independent shop (but they got the parts through Maslack Supply Ltd - affiliated with Auto Value Parts Stores).

The muffler/extension pipe was $200 CAN and the tail pipe was $68 CAN. There were a couple of exhaust heat gaskets as well for $8 CAN each. Labour at the shop was 1.5 hours.

My invoice did not specify part numbers, so I can't help you with that.
 
Bossman said:
I got the muffler/extension pipe and tail pipe at an independent shop (but they got the parts through Maslack Supply Ltd - affiliated with Auto Value Parts Stores).

The muffler/extension pipe was $200 CAN and the tail pipe was $68 CAN. There were a couple of exhaust heat gaskets as well for $8 CAN each. Labour at the shop was 1.5 hours.

My invoice did not specify part numbers, so I can't help you with that.
Click to expand...

Bossman - how does the walker quiet flow sound compared to the stock system? Just wondering if it's about the same or just a bit louder?
 
HokieRunner said:
Bossman - how does the walker quiet flow sound compared to the stock system? Just wondering if it's about the same or just a bit louder?
Click to expand...

Comparison is a little tricky ... my stock system must have had some rust perforations in it that made it sound much louder than would be normal (at the time of replacement). The Walker is fairly quiet so my best guess is that it is close to stock. Definitely not louder ... I don't get much "growl" as an exhaust note when I step on the gas.
 
Bossman said:
Comparison is a little tricky ... my stock system must have had some rust perforations in it that made it sound much louder than would be normal (at the time of replacement). The Walker is fairly quiet so my best guess is that it is close to stock. Definitely not louder ... I don't get much "growl" as an exhaust note when I step on the gas.
Click to expand...
Thanks! I'll keep that in mind as when/if I need to replace mine I'd like to keep it stock sounding.
 
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