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New exhaust system project

Discussion in '1st Gen. Tacomas (1995-2004)' started by CSC, Sep 18, 2018.

  1. Sep 18, 2018 at 10:49 PM
    #1
    CSC

    CSC [OP] Well-Known Member

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    With 327,000 miles on the original exhaust system, a split muffler and a cat code it seems time to change out the whole system. I’ve had good luck with Walker exhaust systems before so I’m giving to a go on my TRD. Cat part number 15826, gaskets (2) 31585, exhaust pipe 55096, muffler and tail pipe 18825, hangers (4) 35725, hanger (1) 35111, upstream O2 sensor Denso 234-4161, downstream O2 sensor Denso 234-4154 and a 2 1/4” clamp 35346. I hope to get started Thursday after work. I’ll report back on how the install goes. 668529D6-5A9D-4D64-B722-B3138CEC92E4.jpg
     
  2. Oct 30, 2018 at 9:57 AM
    #2
    Arctic Taco

    Arctic Taco Serenity-the Arctic Taco, another slow build

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    Denali Park, Alaska
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    dents and missing bits
    Do you have part numbers on the rubber hangers by chance? I just semi finished installing a Borla on my rig with a Walker? adjustable flange cat having a little drama with alignment from my TRD header.
     
  3. Oct 30, 2018 at 11:27 AM
    #3
    CSC

    CSC [OP] Well-Known Member

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  4. Oct 30, 2018 at 2:11 PM
    #4
    CSC

    CSC [OP] Well-Known Member

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    Finally getting around to the install report. I ordered everything from Amazon Prime and only paid for shipping for one item and that was the last item to show up at my house. Total cost $425.91 to my door. The install went smooth, 2 hours. Only hitch and time suck was my inability to remember the orientation of the cat support bracket. Installed it about four times until I figured it out.
    IMG_3066.jpg
    Cat install including the support bracket.
    IMG_3067.jpg
    Muffler and exhaust pipe install. New leaf springs arrive tomorrow :)
    IMG_3069.jpg
    Muffler and tail pipe install.
    IMG_0955.jpg
    Tail pipe to original hanger
    IMG_3068.jpg
    Downstream Denso O2 sensor installed into the new exhaust pipe.
    IMG_0957.jpgUpstream O2 sensor

    I used new SS bolts, washers and nuts at the flanges

    The sound is exactly the same as stock. All in all a good experience and happy ending.
     
    Last edited: Oct 30, 2018
    Saiko likes this.
  5. Oct 30, 2018 at 2:36 PM
    #5
    yotatoy02

    yotatoy02 Well-Known Member

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    This is a little off topic but how does the borla sound? I’m assuming you got a v6.

    I’m considering putting a borla exhaust on with obx headers.
     
  6. Oct 30, 2018 at 3:10 PM
    #6
    Arctic Taco

    Arctic Taco Serenity-the Arctic Taco, another slow build

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    dents and missing bits
    Sounds good, not too much like a Honda with a resonator- throatier I think

    OP thanks for the part numbers. Do you have any idea what the cat support is-OEM or aftermarket
    Are those OEM flange gaskets?
    Is that an OEM hanger on the final one by the tip? Might be the difference between model years as well I guess

    I have a reducing clamp I think I will be using between my Walker cat and the Borla, there is a slight size diff, I cut the flange off of the POS DNA motors cheapo as header that didn’t fit right, and will try that as a transition back to the Borla, most of the 2 hole flange gaskets I have left over are just the aluminized material not actually having the metal center ring.

    The old system was all bastardized and welded so a few of the OEM hangers are mia...
     
  7. Oct 30, 2018 at 3:52 PM
    #7
    CSC

    CSC [OP] Well-Known Member

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    The rusty cat support is original to the truck. Walker makes one too,

    http://www.walkerexhaust.com/catalog/walker-exhaust-systems/e-catalog-lookup/36237

    Full system link,

    http://www.walkerexhaust.com/catalog/walker-exhaust-systems/e-catalog-lookup

    The cat and flange gaskets are from walker. all part numbers are in the original email at the top of this thread.

    The tail pipe hanger is also OEM. OME makes and extension hanger that might work for you. Not entirely sure but it looks like the OME hanger would bolt to the stock location/holes on the frame near the shackle. Here is a photo of the stock hanger,
    IMG_0955.jpg
     
    Last edited: Oct 30, 2018
  8. Oct 30, 2018 at 4:54 PM
    #8
    Arctic Taco

    Arctic Taco Serenity-the Arctic Taco, another slow build

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    Denali Park, Alaska
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    dents and missing bits
    Great, thanks for the info the rear hanger is definitely different must be a model year improvement. Mine just has 2 bolts holding a rubber mount for the hook on the tailpipe. Looks like it bolts up in the same place though.
    Does your TRD have a header as well? I noticed the cat had an adjustable flange. I installed a TRD header and had to use the adjustable flange as the header outlet bolt holes were not parallel to the ground more like 10 and 4 o’clock.
    Great write up thanks for all the info.
     
    Last edited: Oct 30, 2018
  9. Aug 21, 2019 at 11:54 AM
    #9
    panardo

    panardo Active Member

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    csc (op) I snap a bolt trying to replace the upstream O2 sensor, now I am planning to replace these part do you know if this is possible ?
    mine is pretty rusted, so i might need to get gaskets and hardware since i think i will use the grinder tho cut stuff around....

    upstream pipe.jpg
     
  10. Aug 21, 2019 at 6:36 PM
    #10
    Rachelsdaddy

    Rachelsdaddy Well-Known Member

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    It’s called the front pipe. I replaced mine recently, bought it on EBay, 80 bucks.
     
  11. Jun 2, 2020 at 2:16 PM
    #11
    Brake Weight

    Brake Weight But it hasn't rained in weeks...I'll make it.

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    Weld on sliders, fiberglass shell, 12k winch in an Elite Offroad bumper, front Aussie Lunchbox
    @CSC How has your exhaust held up so far and has the sound changed any?


    I've been on a mission the last 3 days to determine what sort of cat back would fit my truck. Thinking I have it narrowed it down I was then on a quest for gaskets and flanges. Then I found this thread I'm about to hijack a little bit. Found very few sources with actual sizes of pipe and ect. So, here's my findings followed by questions.

    I have a 3rz and it looks like most everything for these is 2"
    2rz - 3rz intermediate pipe.jpg
    2rz - 3rz muffler.jpg

    But I wanted a little bigger and it appears the 5vz is 2.25".
    5vz intermediate pipe.jpg

    5vz muffler.jpg

    Then there is OP's muffler which lists as a 2.25" inlet to muffler and 2" outlet. Weird but it is also a different series muffler than the SS 5vz I ordered.
    CSC from AZ muffler.jpg

    So the question is why is there so much variation between 2rz, 3rz, and the 5vz? Factory tuning per engine, what was in stock at said factory, or year model specific? I know my 1999 3rz had a mixed match set of flanges. I'm hoping this will bolt up but do have a spare flange that can be welded onto the intermediate pipe to cat connection if need be. I have the same intermediate pipe ordered as OP, listed for the 3.4l, and I have the SS muffler that I listed for the 3.4l as well. Although I have the 3rz, maybe I'll have a little more 'sound' that stock was.
     
  12. Jun 2, 2020 at 4:35 PM
    #12
    Digiratus

    Digiratus Adventurer

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    Aluminized steel is cheaper but wont last as long.
     
  13. Jun 2, 2020 at 5:02 PM
    #13
    CSC

    CSC [OP] Well-Known Member

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    Brake, The Walker stuff that I installed a year and a half ago still looks and sounds great. It was super cheap and super easy to install. Everything aligned and bolted together very well. Absolutely no codes even with changing the cat and the O2 sensors. Due to the bolted connections, it would be an easy fix if something went bad before the rest. I'm in northern AZ so I don't deal with a lot of snow melt chemicals like the rust belt folks. I'd do it again.

    Good luck!
     
  14. Jun 2, 2020 at 5:25 PM
    #14
    Brake Weight

    Brake Weight But it hasn't rained in weeks...I'll make it.

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    That is correct. I went with the SS muffler and tailpipe but the intermediate is steel.

    Good to know.
     
  15. Sep 22, 2020 at 6:33 PM
    #15
    Sebz13

    Sebz13 Coconut Expert

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    a dropped one and a rusty 4wd one.
    Did you originally have two cats and go to one ?
     
  16. Sep 23, 2020 at 6:51 AM
    #16
    CSC

    CSC [OP] Well-Known Member

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    Only one cat originally
     
  17. Sep 23, 2020 at 7:27 AM
    #17
    Brake Weight

    Brake Weight But it hasn't rained in weeks...I'll make it.

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    Taco pulling 33s and a VW pushing 33psi
    Weld on sliders, fiberglass shell, 12k winch in an Elite Offroad bumper, front Aussie Lunchbox
    If you can get away catless this Jones/Cherry Bomb M80 muffler is a perfect fit for the single cat crowd. You just need to swap over the flanges.




     

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