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Hole in exhaust....need advice on new exhaust!

Discussion in '1st Gen. Tacomas (1995-2004)' started by pt law, Oct 17, 2011.

  1. Oct 17, 2011 at 8:51 PM
    #1
    pt law

    pt law [OP] Well-Known Member

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    So I got in my truck this week after not driving it for a few days (wife was driving it) and it sounded funny. Look underneath and found hole in muffler (see pic). Salt kills...

    So I need a new muffler. I was thinking of just replacing from the cat back. I do NOT have the money to spend on a cat back performance exhaust and really am not looking for a exhaust for the sound, so basically want to get a quality replacement that will bolt right in.

    I could use some suggestions on something that is well made and priced right. I have heard of Walker exhaust but that is all I know. Suggestions would be appreciated.

    I did some searching and everyone has posted about replacements for the sounds...flowmaster, magnaflow, etc, but really just want something that is cost effective and as quality made as possible so it will stand up to the salt.
    Thanks

    [​IMG]
     
  2. Oct 18, 2011 at 5:33 AM
    #2
    defleppardsg

    defleppardsg Well-Known Member

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    Bump. I have the same situation.
     
  3. Oct 18, 2011 at 6:01 AM
    #3
    TIPICOTACO

    TIPICOTACO Well-Known Member

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    I had a very similar situation w/ my last truck (97xtracab) Ended up just bringing it to my local muffler guy and had him bend some stainless pipe from the cat back and weld on a magnaflow muffler. it ran me just over $300.

    If thats too much for ya, and your piping is solid, just weld on a new muffler
     
  4. Oct 18, 2011 at 6:28 AM
    #4
    HammerHead

    HammerHead Well-Known Member

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    I don't think you can go wrong with a Magnaflow. Based on how much you have to replace, it would likely cost you anywhere between $100 - 350.
     
  5. Oct 18, 2011 at 6:39 AM
    #5
    skytower

    skytower Well-Known Member

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    Keep in mind, aluminized replacement mufflers/systems have a life expecantcy of 2-3 years in salty areas. Balance that with the cost/labor of a stainless replacement and how long you plan on keeping the truck.
     
  6. Oct 18, 2011 at 8:20 AM
    #6
    pt law

    pt law [OP] Well-Known Member

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    I found a guy parting out his totaled tacoma. He is willing to sell me the exhaust piping and muffler from the cat back for $50. Anyone ever do this themselves? Should I be able to take apart right behind the cat and bolt the replacement right on (its OEM)? If his in good condition, I am thinking about doing this.

    If his is not in good condition, then I will look into Magnoflow and or something stainless and NOT aluminum due to salt. Any other recommendations for quality stainless replacement (not concerned about the sound)? Thanks.
     
  7. Oct 18, 2011 at 8:23 AM
    #7
    707eric

    707eric Member

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    Due to the bends in the system you may have a hell of a time trying to remove and install the exhaust all in one piece.
     
  8. Oct 18, 2011 at 10:55 AM
    #8
    hulkit

    hulkit Well-Known Member

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    [​IMG]

    i did that with my 22-re 90 pickup when it was rusting holes

    dont have any pictures of when i did it but i just sanded cleaned pipe applied aluminum tape and painted it black and it worked great for the rest of my trucks life +11 months or so

    theres always solutions besides replacing the cat and the tape lasted through pressure tests that i did just to make sure it wouldnt pop sometime

    just my .02 cents
     
  9. Oct 18, 2011 at 11:03 AM
    #9
    Yamaha Dave

    Yamaha Dave Well-Known Member

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  10. Oct 18, 2011 at 11:34 AM
    #10
    skytower

    skytower Well-Known Member

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    Hitch and wiring, aux back-up light, rear strobe lights, radio and underseat sub.
    I was referring to the aluminized steel. It lasts longer than bare steel.

    The OEM exhaust will be difficult to separate at the flange. Soak with PB Blaster for a day or two. Use heat on the bolts. They will be easier to remove when hot. MAPP torch will do the job.
    If you must, cut off both flanges and replace with a sleeve. It won't work as well as the flange, but if it's badly rusted, it may be your only option. Welding in a replacement flange is the other way...
    Inspect the flange to see what you're dealing with, and proceed from there.
     
  11. Oct 18, 2011 at 3:09 PM
    #11
    Blackdawg

    Blackdawg Dr. Frankenstein

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    :eek: thats a ton lol

    i just had a new magnaflow 14'' muffler and 2.5'' pipe out witha 3'' tip and it was just 180 bucks. i dig the tone :cool:
     
  12. Oct 18, 2011 at 8:34 PM
    #12
    pt law

    pt law [OP] Well-Known Member

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    Will the flange have rusted together? :confused: I had thought that if I could get the bolts out, which I know may be a hell of a job, that the flange would just separate. Is that not the case or I am going to have to fight the flange in addition to the bolts?
    I have been learning to do my own wrenching so would like to try this without getting myself into a place that I cannot get out of. Thoughts? I can post up a picture of the flange tomorrow.
     
  13. Oct 20, 2011 at 7:09 AM
    #13
    TIPICOTACO

    TIPICOTACO Well-Known Member

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    yea... things aren't exactly cheap here in the Garden State :(
     
  14. Oct 20, 2011 at 9:48 AM
    #14
    skytower

    skytower Well-Known Member

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    I don't know if the bolt is welded to the flange, but the bolts and nuts are the first to rust to the point of needing to be cut out. The flange has a wound, metal gasket inbetween the flanges. If the flanges are salvageable, get a new gasket(factory) and bolts(hardware store).
     
  15. Oct 21, 2011 at 1:48 PM
    #15
    scoostraw

    scoostraw Active Member

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    I just bought a 2000 extended cab and I have the same issue. Pipes all look ok but the muffler is splitting down the side. Has anyone here replaced the single piece pipe from the cat back? Can you get the new pipe on with the truck sitting on the ground?
     
  16. Oct 25, 2011 at 7:33 PM
    #16
    scoostraw

    scoostraw Active Member

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    Well I Realized that my muffler is splitting at the seam. The pipes and everything else are fine. So I used some Permatex muffler goop and some hose clamps to fabricate a repair. It's been 3 days now and it's holding ok. Eventually I'll fix it properly.

    [​IMG]
     
  17. Oct 25, 2011 at 7:35 PM
    #17
    ETaco23

    ETaco23 Marshall offroad Fabrication

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    Just get a Dynomax super Turbo muffler or a Borla.. And get it welded in...
    Both sound great!
     
  18. Oct 25, 2011 at 7:37 PM
    #18
    fletch aka

    fletch aka www.BeLikeBrit.org

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    To bad your not in California, I have a near new OEM exhaust for sale, cheep.
    Less then 1000 miles before I swaped it out for the TRD cat back.
     
  19. Oct 25, 2011 at 7:40 PM
    #19
    pt law

    pt law [OP] Well-Known Member

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    Your a 2nd gen. I believe the 2nd gen exhaust is different then 1st gen.
     
  20. Oct 25, 2011 at 7:49 PM
    #20
    oneBIGroom

    oneBIGroom SSS

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