Frozen exhaust bolts everywhere

My stock muffler has rusted through after only 24 years. So I'm getting ready to install the BRExhaust/Bosal cat back kit, and as expected, all the bolts are pretty much solidly rusted. As far as I can tell, there is some kind of hanger bracket that is bolted to the exhaust flange / cat. I broke one bolt and rounded the other. I'm guessing I need to replace this hanger, but so far have been unsuccessful in finding another one. I guess I have to cut it out now, but it's going to be a pain getting anything bigger than a Dremel in there. Any thoughts on saving or replacing it? I can't tell if the nuts are supposed to be part of the bracket or not - they're just blobs of rust now, pretty much welded together. I don't imagine the PB blaster will help much.



The O2 sensor bolts are frozen too - I'd like to save that too as it apparently still works.

 

I think @Kristi with a K just ordered this.

 

Soak with pb blaster or similar for 24hrs. Then use a map torch to get the nut and bolt hot. Hit with impact and should break loose. When you reassemble use Anti-Seize and should be good.

 

<Colin Jost>
In other news, a local truck owners' exhaust system finally succumbed to decades of water and road grime decay. Said the owner "The reliability of this 24 year old part makes me reconsider the overall reliability of this vehicle."
</Colin Jost>

 

You’re lucky to have gotten so long of a life out of that exhaust. I’ve done mine 3x living in snowy and salty NJ. I just always replace with standard bolts from lowes or Home Depot. They aren’t to spec but as there is no serious load on these (other than thermal) I have found them to be a cheap and satisfactory alternative. Don’t bother with stainless and just use a little anti seize if you anticipate having to disconnect again. It might help. Good luck.

 

I have been using universal Hangers and exhaust clamps for the last 25 years.

I always have them no time delay waiting on parts.

 

Yes I am, especially in the snowy and salty midwest. The sarcasm is clearly lost on some readers. 24 years for any part on a daily driver in the midwest is pretty crazy. But as we know, Toyotas especially of this era are well known for longevity, and this is just another example. My BIL put 320k+ miles on his 2000ish Corolla and only changed tires and belts - it still had original brake pads when he sold it.

Anyway, a Dremel tool, angle grinder, and sawzall made short work of the old exhaust. I just hope the BRExhaust goes together well. I'm not sure what to expect from this budget kit.

 

I ordered a Brexhaust combo kit on Rockauto for my 03' double cab 4WD Tacoma after dremeling, PB blasting, propane torching, and 6 point stripping my original exhaust flange bolts behind the cat. Everything fit very well for my rig so if you picked the right parts for your Xtracab you should be fine. My order didn't have an insulator/hanger so I left an an old one installed.

After this project was finished and I could hear my exhaust way better (old muffler had a huge hole), and discovered another exhaust leak on the gasket that links the downpipe to the front of the cat converter...Anybody know If I can unbolt this linkage from wheel well and slip a gasket in without loosening bolts anywhere else? Thanks.


EP.

 

I was able to do that. Truck was down for some time though, and I sprayed PB Blaster on the bolts for a week before I even tried to get them off. I had to do both driver and passenger side to get enough room to get the gaskets in an out. I was really lucky (and patient)- able to remove the nuts without an issue and didn't destroy the studs. Sounds like you already know the pain of working on those exhaust parts, so be prepared for the worst and have new studs and nuts on hand.

 

I decided to try this. T'was about the only hanger I could see that might work unless I wanted to fork out the 50.00 for a Toyota one.

$20 Walker Exhaust 36237 Exhaust Bracket

https://www.amazon.com/dp/B000C949PG?ref=ppx_yo2ov_dt_b_product_details

I had to make it work ('01), however I do believe this is for the '99. Although looking at yours I'm not quite sure how it'd work unless it attaches right to the flange. Holes don't seem big enough though.
I just ended up putting the arms through the bushings 1st & then used a large-ish hose clamp. A 2 1/4 exhaust hanger came up too short. Anyway, it's holding fine & I can figure out something else (maybe weld it on) down the road....

 

This truck should clearly be parted out. Everything but the exhaust.

Edit, plus who owns a truck 24 years????

 

Dude, yes. What a royal PITA! I'm really considering buying a Harbor Freight oxyacetylene backpack torch as my current Coleman/propane green tank torch takes way too long. But taking to a exhaust shop is more practical - I don't fabricate anything.

The few, the proud, the "pride in your own workmanship" owners.

 

Yep, that’s very close. It kind of cradles the flanges, and the flange bolts go through it and attach it to the backside of the cat flange. I ended up dremeling the bolts off, since I couldn’t fit a bigger cut off tool in there. Then I had to take out this hanger/bracket/cradle thing and cut off the other half of the bolts that were pretty much welded on. Same with the O2 sensor studs.


So I didn’t need to replace it. I reused it and all the original isolators. And the dremel, angle grinder, and a sawzall make short work of that original exhaust.



Got it all buttoned up and let it run for a while. Ah, the smell of burning permatex. I took it for a ride too, and it’s still noisy as hell, but at least the exhaust is quiet.



Speaking of which, I noticed the suspension parts were getting pretty rusty and those Bilsteins were looking (and feeling) pretty rough too. I guess I know what the next project is.

 

My newest vehicle is 22 years old!!