Cat back exhaust comparison and swap. 2nd gen to 3rd gen.

I couldn't find much info on this to I thought this could help some people out.

2005 base regular cab 2.7 4 cyl original exhaust with 195k on it.

I picked up this 2016 double cab short bed exhaust off craigslist for $50. The guy swapped for a TRD exhaust at 40k. It looked like it might fit from the pictures in the ad but no go when I pulled my exhaust to compare. The only two issues I can see right now are:

The new exhaust is 4" longer on the cat side.
The rear hanger is 90 degrees off.

I was thinking about chopping it just after the axle anyway so that will take care of the rear hanger.

Maybe someone can chime to help with the rest. Do you think I can take it in to a muffler shop and have them cut the the cat flange off and cut the new to me exhaust to fit?

 

Yes that’d be an easy fix for an exhaust shop

 

Thanks!

 

One more question. Has anyone used a 2.25" butt joint (or a different size) on these 60mm pipes. I forgot about those and it would be an easy and cheap fix if it didn't leak.

 

I think @hemitruk did something similar to put a gen3 exhaust on his gen2

 

Yea I did . I had a sleeve spot welded in though .No leak .
Will look for pic when I go home . Someone else mentioned they tried and it leaked .


After 4 years . Didnt weld cause mines lowered and easier to remove if I need to.


People have used this hanger with correct angle . Also mine is a V6
@JvStarr88

 

It's close enough for a muffler shop to chop and weld it in, I've seen others put a 3rd gen exhaust in a 2nd gen with minimal modifications.

 

What about the exhaust pipe diameter ? Are they identical?

 

mine was

 

Really great info! The 90 degree hanger is a good idea if you don't want to chop. I know this was a while ago but do you remember if you used the 2.25" sleeve or did you manage to find a 60mm one?

They are the same. The only differences I could see was the 4" length difference, rear hanger turn that is easily fixed with the hanger listed above and there aren't any heat shields on the gen 3 muffler. I didn't butt up the faces of the union to the cat but the gasket was the same size.

 

Clamp is 2.25 . Dont know if they make it in metric . Also can see some signs of slight leak (4 years) but at idle dont feel any leaks . You could put a little hi temp silicon around joint and clamp . I did not . If cut is perfect shouldnt be a problem to me anyway

 

Thank you. I'll order one. I didn't see any 60mm ones and I could find any info of the 2.25 fitting but that would be the closest. I can at least get thing on the truck and if it is leaking too much or bothering me I'll get it welded together.

 

Just wanted to post an update. The next day after I bought this 3rd gen muffler I picked up a 2018 TRD muffler for free and ended up taking that into the muffler shop to get welded on. It had more rust than the other one I bought because it came from Oregon but was two years newer and both had about 40k miles on them. Works great. I ended up cutting it and doing the axle dump.





The muffler shop was awesome as well.

 

Also the 2.25 clamp I bought didn't fit for me.