URD Y-pipe woes

With catalytic converter theft being so rampant these days, I decided to get a URD Mk. 2 y-pipe for my 2nd gen. I installed it a few days ago and started hearing a weird rattling noise coming from under the truck. I quickly realized that the y-pipe is in direct contact with the transmission crossmember. I tried loosening things up and tweaking and shoving the pipe around, thinking maybe something wasn't seated quite right, but nothing changed. I did a bunch of searching around the interwebs and can’t seem to find anyone else having this problem. My truck is an ’08 Prerunner. URD’s website said this thing fits both 4x4s and 4x2s. This is my first time messing with an exhaust system, so user error is a definite possibility, but as far as I can tell, everything is where it's supposed to be. Did I install this thing wrong? Any thoughts on what might be causing this or how to fix it? Maybe I should just put the stock y-pipe back in and put a Cat Security plate on it like I probably should have done in the first place?

Any insights would be greatly appreciated.

 

looks like the missed they initial bend by a couple degrees.

 

I was wondering if a manufacturing screw up might have been a factor. I'm generally pretty handy and usually don't mess things up too bad, so this has had me scratching my head. I just sent a message off to URD explaining the situation. Probably won't hear back for a couple days though.

 

Worn/aged engine mounts can play a part in that as well.

Regardless. The easiest option, is a little heat, and a pry bar. Not nice or pretty, but it will help.

All other "better" options are costly and time consuming.

Dealt with the same on a friend's truck. His is an '09.

@Lucario Runner

 

I checked the engine mounts and they're still in good shape. The engine seems to be sitting right where it's supposed to and doesn't have a lot of play/isn't sloppy.

I reckon I'll wait to see what URD has to say before I go trying to tweak it myself.

Thanks for the replies, guys. I appreciate it!

 

Sorry to hear about your issue… agree that it definitely looks like a manufacturer missed the bend mark… maybe should have done straight for another 1.5-3” before the drop bend. I would NOT start tweaking on it, especially with a torch yet… wait for word from URD. Once you modify, usually always voids any type of warranty.

That said… the little time you drove it, other than the rattling, are they worth it? Power and torque gains, sound?? Looking at a set for my 3rd Gen…

 

Unfortunately, I don't really have any good answers as far as power, torque and sound gains. I usually go pretty easy on things when first shaking them down, and once I heard the rattling, I figured something was wrong, so I never really gave it the beans. I did have it on the freeway briefly, and passing felt a little more effortless than it had before. As for sound, it sounded a bit drone-y to me, but I think that's because it's vibrating/resonating through the frame of the truck, so I'm not getting the pure sound of the exhaust. The build quality, aside from the bend being off, is great. It's a really solid piece. I would recommend it if you're thinking about it. Every other post I've seen on here and the 4runner forums has people speaking highly of it. Seems like I just got unlucky with mine.

 

Agree that you don't want to modify anything until you hear back from them. As a last resort, I'd circle the area with a Sharpie, remove it and beat it in a little with a hammer. Not the best option but I HATE rattles and clunks.

 

Yeah, I definitely won't mess with it unless it's a last resort. I'm with you on hating rattles and clunks. Especially when it's as pronounced and persistent as this. I like the hammer idea. Might mess with the flow of the exhaust a little, but I can't really see it being a problem, and should be a lot easier than trying to tweak the bend on the pipe.

Fingers crossed I hear back from URD and can get some kind of resolution through them. If not and I have to make do with this pipe, I'll try hammering it. Either way, I'll update this thread. Hopefully it'll be helpful if anyone in the future runs into this issue.

 

There is a dyno before and after, in my N/A dyno thread. Not of their newer equal length Y.

 

Interesting. I was just looking to protect my truck from cat thieves, but nice to know I'm also getting some bang for my buck.

 

Worse case take it to a muffler shop and have them rework it. Does the pipe route anywhere near the transmission pan? I’ve got a deep pan on my 15 and have thought about installing one for the same reason.

 

Yes, it passes about an inch beneath the transmission pan.

 

Any updates? Is it resting on the crossmember or just rattles against it with the engine vibration? Can the y-pipe hanger be modified so it pulls it away from the crossmember?

 

The hanger will have no impact on the y-pipe. Due to the fact that there are no flex couplings in the y-pipe.

Poly engine mounts. Bend the y-pipe in that location for clearance (hammer, heat, whatever), or have it re-fabricated.

Have to find an exhaust shop that works with 304 stainless, if you want them to fix it and retain the stainless integrity.

 

OP, was this ever resolved? I am wanting one for my 3rd gen but they are not available right now. If it is un molested and you are going to remove it, I would be an interested buyer.

 

So I spent most of last week emailing back and forth with URD running through their checklist of potential fixes, most of which were pretty much the exhaust troubleshooting equivalent of “try unplugging it and plugging it back in,” and none of which made much of a difference. Their final suggestion was to drive 400 miles to Santa Ana where they have an exhaust guy who could sort it out. So today I ended up going the hammer route. It bought me maybe 1/16-1/8” of clearance.

I’m pretty sure the fitment issue is due to a manufacturing screw up. I spent a lot of time under my truck this past week and noticed just how crookedly the pipe is actually sitting (I’ll include a couple pictures). This should have been a simple bolt in job. My truck is otherwise completely stock. I mentioned it a couple times in my correspondence with URD and they flat out ignored it both times. In the end, I figured whacking it with a hammer was the quickest and easiest solution and I’m all out of patience for dealing with it. I don’t need it to be pretty; just functional.

 

Easy fix. Should only get the occasional tinging sound under more uneven terrains now.