Think I may need to replace Catalytic Converter on my 2003 Taco

Should I put loctite or never-seez or nothing on the spring bolt threads?

 

You don't really have to put either. In my experience, loctite burns off and doesn't do anything when used on the exhaust system. Especially right next to the cat where it gets stupid hot

 

Anti seize would be good, but I have a feeling you’re gonna be taking it apart again soon...

 

One other stupid question. The gasket has 2 sides. One shiny and one composite material. I am assuming the composite side goes inside the exhaust pipe and the shiny side faces the Cat pipe?

 

it's a crush washer so it gets squished when you tighten it all up.

The ones I have used didn't have that "shiny" side of it. but the orientation you listed sounds right to me

 

Put the shiny side to the smoothest flange surface.

But, yeah, it compresses and fills in the imperfection on the flange surfaces.

 

Do you place the gasket in and just push it in and it will stay? Forgive me I have not taken the pipes a part yet. I dont see a picture or video online how its done right with this type of gasket. I have seen the donut gasket videos.

 

Not really sure how to explain it but there’s a male pipe on the end of the cat that then goes into a “female” larger pipe on the catback. It’ll slide right over that male part and that’s what keeps it from falling out and keeps in lined up. You’ll see what I’m saying when you take it apart.

 

Is it ok to use a spinning wire brush on the end of a drill to clean the rust on the flange and pipe where the gasket is or maybe was if it is rusted out?

 

yes, that should work just fine.

 

I just thought of something. If you look at the picture of the good and bad flange I am going to have to cut both sides of the bad flange where the holes are to be able to mate the holes of the good flange to the split flange.

 

Hope it doesn't fall a part when I start cutting lol

 

Literally the next day after posting the light came back lol. Been on ever sense.

 

Ok. So I took the rusty flange a part and the gasket was completely rusted out. Half of it was gone. However, the split flange I bought was too big. Bad measurement on my part. I thought it was a 2.25" pipe but it really is a 2" pipe. Now that is gonna be a problem because the holes on the existing flange are 4.25" center to center of the holes. The 2" version of the same split flange I just ordered is 3.88" center to center. However it is an oblong hole so there might be enough but I doubt it. Do I really need to use spring bolts as well because only the oblong holes on split flanges will allow the spring bolt to go through it and stop on the next existing hole which only allow the remaining thread of the spring bolt to go through. I am not sure what the heck to do now.

 

Have a new flange welded on

 

There were never spring bolts used on those flanges to begin with so is that even needed?

 

No but it will keep them from loosening when the gasket compressed or the flange deforms more. Which one if not both will probably happen

 

Well there is enough strong meat left to put a split flange on it if I can find one that lines up the holes with the existing flange.

 

I bought a weld on flange to replace my rusty one that looked exactly like that ^

Holes didn't line up either. Ended up elongating them with a dremel and then using the welder to "fill" the inner portion of the now elongated holes. Was pretty hacky but it worked.

 

I hear ya. This is the kind of split flange that was holding it together for 4 years. I am thinking the rusted out half a gasket that was left caused the major part of the leak. Before I go with your weld idea which I agree is better I want see if I can get by for a year or more using a new gasket and a better split flange.