Catalytic Convertor rattle and exhaust questions...

Hi all,

I have a 2015 SR5 4.0 with 80K miles. I've been having exhaust rattles that I ignored but when the AC clutch went I started looking around since I was under there. Frame looks OK, back where the trailer hitch is looks like crap....

First; Those silver heat shields are held on with iron hardware that is rotting off and the aluminum. I replaced the bad ones with SS harware and large washers. Do I really need that tin, some of of them are in places I won't be able to fix with the exhaust in place..?

Second: The tin on the front cat rattles, the mounting screws rotted right off. I replaced the hardware with SS bolts and it's tight but still rattles. I took it off, there is some sort of band around the cat, between the cat and the tin..that is rattling because its worn...Anyone run into this and what did you do..? should have taken pics.

Third: In general the exhaust looks good considering it's SS, except where the joints are, they are iron and badly rusted. Can't even tell the bolts are bolts.. I can't be the only one, do you replace the exhaust or wait until it falls off?

I'm disappointed in the rust this truck has, passenger inner fender has/had rust where the P/S reservoir mounts and other areas. I keep it pretty clean, it's not my DD, I've been driving Toyota trucks since 1985, taco, tundra, 4runners, except for my 85 pickup this is the first one that has this much rust. My last 4 runner went 16 years with absolutely no issues...

Thanks
D/S

 

Sorry to hear about the issues. The rust is nearly ten years old. The places it is rusting have the widest temperature swings and also are some of the most exposed when it comes to water, brine, grime etc. and are some of the most difficult to keep clean.

It may just be getting close to time for a new exhaust.

 

the "tin" are heat shields, mine have been long gone for a while now. no issues. As far as the rust, do you have your truck fluid filmed or woolwaxed ever? Even in NJ, when it snows, they use salt, and you need to protect your underbody. I would suggest you look into doing that sooner rather than later. as far as the exhaust, I would wait until you have an issue, just my 2 cents

 

Something else to look at is the vertical supports on the front cats (at least on a V6) - they will rust through where they're bolted at the flange in a way that is hard to see unless you tug on the cat, and then vibrate like hell at low RPMs.

 

I don't see a support, there is a hanger downstream of the cat, it's got a flange going to the manifold about a foot up stream... Is that it, because that's what I was referring to when I said the joints were rusty. I can hear the rattle from the cat when I'm under there and bang on the down pipe with my fist..

If I keep it I will probably take it somewhere to get sprayed, I check the frame every couple years and touch up any areas with rust-(not much)..I'm getting older and crawling around under vehicles is becoming not so great an option... I have a classic car that requires lots of attention and that is becoming an issue to... the trans needs the fluid changed-I'm not rushing to do it..LOL

Did I mention that the metal P/S return line under the balancer had flaking rust you could peal off with your finger nail, only on one bend...But it would have rusted through if I did not deal with it... That sort of thing disappoints me..

Thanks,
Doug S