Muffler/exhaust replacement question

Hi all,

I've recently had a large (fist sized) hole blown out in the rear of the muffler from rust. When looking online at replacement exhaust parts, everything with the muffler seems to be cat back/resonator back, and include a flange. But looking at the exhaust on the truck, it seems to be one piece all the way from the header to the exhaust tip - am I missing a slip joint or something? (2001 2.7l ext cab 4x4 5spd)

This will certainly sound silly, bit what's the process for replacing mufflers? I've only replaced an exhaust section on my Celica but it was bolt in with the flanges. I'm hoping to not have to replace the whole exhaust length in this truck since most of the upstream tubing is in decent shape (except the flange at the exhaust header is completely rusted so I doubt that will ever come apart). Do you typically just go to an exhaust shop and they'll cut and weld in a new section? Any recommendations on muffler to exhaust tip parts? Any recommendation on exhaust shops too? Should I avoid the big chains? I'm located in the Boston area. Thanks

 

I just did that muffler replacement on my 01' Tacoma. I found a muffler the exact length and configuration that I needed to replace the original, and just cut off the original with a Sawsall, and used 2 stainless band clamps to affix the new muffler. A little tip that I learned long ago about cutting pipe "reasonably straight" is to first put a stainless hose clamp around the pipe exactly where you want to cut, and use that as a guide for the sawsall blade. Be careful tho NOT to cut the hose clamp! ;-)

As for hangers, the originals are welded to the back of the original muffler, so I used a 4" grinder to cut them off as-close-as-possible to the muffler and then used a stainless hose-type clamp to fasten the hangers to the new muffler system after it was installed; works perfectly, and I love the sound; sounds very V8'ish! The whole process took me about an hour. I DID clean up all of my cuts with a grinder prior to assembly.

Incidentally, the actual muffler that I chose was a stainless steel guaranteed-for-life, MagnaFlow XL 3 Chamber Muffler #13745 from Summit Racing.

 

Would love to hear this set up. Im looking at replacing the stock muffler as well

 

Having a dynomax ultra flo put on my truck soon here as well. I’ll let y’all know how it sounds

 

I make it easy. buy a Bosal or Walker muffler and cut off the old muffler. the hangers are already welded and use one clamp to join them

 

Thanks for all the feedback.

Kleenax, I'm looking to cut in pretty much the same spot you did, right upstream of the muffler. But I'm hoping to get something with the tailpipe out the back included

Frizzman - does the Bosal or Walker muffler come with the tailpipe as well? I'd love if all the brackets were already on

 

The easiest method would be just going to a muffler shop and have them cut out the muffler and add a new one. They don't need to mess with any of the rest of the pipe if it's in good shape.

 

On U- tube there is a grate video of a guy replacing his while system on the cheap, certainly worth watching. With this truck the possibilities are endless.

 

My tailpipe was in GREAT shape (as was the pipe from the muffler to the back CAT), so for the $8.99 band clamp, I kept my original tailpipe. Like I said in my original post, the original (cut-off) hangers worked fine simply clamping them to my new muffler.

 

Incidentally, the Band Clamp to buy (you need 2) is this one:
https://www.summitracing.com/parts/sum-681225

 

yes, the bosal and walker have a short section in front of the muffler, and then the complete tailpipe as one piece

 

Anymore Walker Exhaust is all I use

All Bolt on you get find it most places .