Exhaust Leak?

Yesterday everything is good, this morning get in the truck to go to work. Turning out of my driveway I hear a rattle, sounded like a bolt fell out or something similar. Very brief sound, so quick I wasn't sure I'd even heard it. Then as I'm driving I realize my truck sounds much louder than normal whenever I hit the gas. Idling it sounds normal but accelerating it sounds like I added an exhaust system, seems to be coming from under the passenger side floor. So, did something most likely rust through and now I have a leak? As far as I know it's the original, 2009 exhaust system.

Assuming it's a hole, what are my options for repair? I know there are the really cheap wraps and such, but if I decide to replace everything what should I look for?

 

Many posts on many systems but for stock dealer is pricy but it lasted 12 years in MA salt.
All the major auto stores sell muffler with tailpipe or not, and the muffler to cat section (intermediate) for about $125 they work fine and use stock hangers so quick install.
Online they all have them too like Rockauto, Carparts, Carid but you have shipping.
If you want more noise (performance really doesn't change) and have extra money (watch out for that drone noise) lots of posts on them.
I put a Walker SS Quiet Flow muffler and intermediate pipe $114 (lifetime warranty) from Advance on 4 years ago still OK and painted high heat black $6.
Low price with low drone and on full throttle you hear it. You may only need a muffler. Stock muffler has the tailpipe welded on but you could saw it off and use.
Usually that intermediate pipe is junk at the front flange and the bolts/springs are rusted solid and donut falling apart but they make a cheap kit for that too.
All depends on what you want as always.

 

Agree with @muddog321

First thing to do......is crawl under the truck. Figure out what you need.
Or
Take it to the local muffler shop.

The "wraps" are temporary at best, many times the "wrap" won't stick. A stainless steel system will be a lifetime setup, but it will be expensive.

Don't waste your time & effort reusing bolts or gaskets. Just replace them.

 

I know it's hard to tell until I look but if the noise seems like its under the front passenger side is that after or before the cat?

 

Yes......either. Need to LOOK.

 

leave the leak, enjoy the fumes . . .

 

Leak is big and obvious, at the joint where the Y and cat are bolted together. The bolts are dust so they'll need to get cut off. What do you all think the cheapest GOOD fix would be.

https://imgur.com/gallery/WaL63wr

 

Looks like a good fix would be a CAT Back system.

That joint is clearly leaking. Just cut the bolts off with a hot wrench.

Or go to a muffler shop.

 

You can get a autoparts store cat back system pretty cheap ( $200-300), but they typically only last a few years. Sure, many have warrenty, but you have to do the work over and over.
The OEM system is like $560 list, some dealers will beat that if you ask. My local dealer does it for $412 if i buy online and pick up. If it lasted this long, to me its worth it for the OEM parts that fit right and last a while.

https://parts.lynchtoyota.com/search?search_str=muffler

 

Looking at the various cat backs and I don't think they'll fix it. My leak is forward of where it looks like all the cat backs attach. And how many cats does the 4.0 have?

It's at the end of part number 10:

https://www.carid.com/2009-toyota-t...-2569873132.html?parentsubmodel[]=ENGINE|4.0L

 

Edited: OK i see, your leak is upstream one more joint. On the y pipe joint that is part of the left Cat? Upper left hand corner of this pic?



If the pipes themselves are still solid, you might be able to just get new gasket/seal and hardware to bolt it back together. Kinda just looks like the hardware rotted out. Otherwise you need to replace that whole y pipe with cat as a part of it, or the better option is to have a muffler shop weld/repair the joint that is leaking.

 

vtown,
you're exactly right, it's the connection with the integrated cat. Fingers crossed it just needs a gasket or welding because that assembly is $1100!!!

 

I just had that leak myself last year. The flange was basically destroyed, so I took it to a local muffler shop who cut the old one off and welded up a new one using stainless steel. Cost me a few hundred $. I was almost thinking of just biting the bullet and getting all the new OEM pieces... except then you need to pull everything off including the exhaust manifolds from the heads. So many ways that could go wrong with the old rusty bolts...

Here is that thread: More exhaust leaks | Tacoma World

 

I have a leak at the flange that opens up more in cold weather. I can tell how cold it is just based on how loud it is. It’s been that way since 2017.

 

I just watched your video, that's exactly what mine looks like, mine might actually be a little worse. I'm taking it in on thursday, hopefully they can fix it quickly.

 

winning.

 

I hate to even mention this because I have less than 50 posts but I have a Double Cab/long bed Gibson stainless exhaust sitting in my garage as I initially ordered the wrong model. Just installed the correct one and it’s a nice throaty rumble and fitment is great/easy to install. If that’s what you need and are interested DM me. I live in central CT.

Edit: cat back system so won’t help with the upstream flange leak but if there is a problem with the flange after the y-pipe this works great.

 

Slyr, thanks for the offer but mine's a short bed.

I'd leave it if I could, the noise is annoying but no check engine lights (yet). But it won't pass inspection as is so needs to get fixed. Wish I knew how to weld, I would do it myself. Seems like a pretty easy fix other than needing the welding.

 

Well..
Turns out my front cat needs replacing. Both ends of.the short section cat are shot. $1200 total, since it's in the shop I'm having my belt replaced as well. It's been needing it, cracks are obvious and I'm probably lucky it hasn't broken.