[rdublin]

After way too long, I finally collected all the pieces I needed to replace my cats which failed due to a leak in the "Y" downpipe joint. I found a good front cat from a wrecked 80, but the down pipe was partially crushed, so I cut the "new" cat off the crushed downpipe with plans to weld it up to my downpipe after I repaired the leak. Unfortunately when I cut my downpipe just below the "Y" I found that it had failed due to corrosion. The flat faces on the two incoming pipes were nearly paper thin. (see first two photos, the third is what it is supposed to look like - unfortunately from the crushed downpipe) There isn't much left to weld, though I am contemplating trying to braze it. So, I am looking for suggestions on repairing this downpipe, if possible.

Failing that, does anyone have a good downpipe available? I don't need another cat and am hoping I might be able to find a good downpipe here in Sacramento. CARB doesn't allow junkyards to sell used cats, so they typically cut them off and sell them for scrap. I am hoping they just torch them off and that I might be able to get the remainder of the downpipe from the truck. I'll check tomorrow but imagine they will not be open until Monday.

Thanks,

[60wag]

I too am looking for a replacement Y pipe. I've heard the OEM ones are silly expensive. My current one has already been reworked by a muffler shop before I bought the truck. I've been trying to track down a loud buzz/rattle that appears to come from the area of the Y pipe. I've removed any brackets and heat shields that can be removed. The cats, heat shields and mounts look good. I suspect one of the booger welds on the Y pipe is cracked. Does anyone make aftermarket components like the Y pipe or are those always custom fabbed by muffler shops?

While we're on exhaust systems.....
Why isn't there any type of a flex joint between the engine and the cats? On many cars with transverse monted engines, there is a flex joint to allow the engine move on the mounts without stressing the entire exhaust system. On my FJ60, the exhaust was routed inside the frame very close the the transmission. When the engine was under higher torque, the exhaust didn't need to flex much. On the FZJ80 with the exhaust outside the frame, a slight movement of the engine requires a significant movement in the exhaust pipe unless the pipe is flexing - no wonder the Y pipe fails. I saw an HJ75 with the same arrangement: rigid pipe leading off the exhaust manifold and down outside the frame. Engine torque had caused the pipe to fail.

Has anyone added a flex joint to the system?

[john_eckels]

There are a number of options that are a lot less expensive than the OEM stuff which I think costs around $1300


Here's info on Borsa
http://forum.ih8mud.com/80-series-tech/175113-bosal-oem-exhaust-lifetime-warranty.html



Discount Converters has them for around $250
http://www.discountconverter.com/

[rdublin]

Originally Posted by john_eckels

Discount Converters has them for around $250
http://www.discountconverter.com/

I checked their website and they don't show any direct Toyota applications later than 1995, which is when OBD-II kicked in. The problem in Kalifornia is that CARB must certify any non-OEM cats for OBD-II vehicles and thus far I have not found any companies that offer that product. Do you happen to know if one of thier universal types fits and is 50 state legal?

Of course, that still doesn't solve the problem with the Y pipe...

[elmariachi]

Hey guys:

http://cgi.ebay.com/ebaymotors/ws/eB...m=190067382258

How will Cailfornia emissions know? Were 1996 trucks not all built to comply with Federal Emissions?

[rdublin]

[QUOTE=john_eckels;2703682]Here's info on Borsa
http://forum.ih8mud.com/showthread.php?t=175113
QUOTE]

Ah, this looks better, http://www.bosalna.com, but I have a suspicion they don't sell these in Kalifornia due the the little (a) listed under the cat part numbers, which appears to mean Federal only. I'll call Monday to find out. FYI - the downpipes and front cat are $615. Thanks for the lead in any case!

Cheers,

[rdublin]

Originally Posted by elmariachi

How will Cailfornia emissions know? Were 1996 trucks not all built to comply with Federal Emissions?

Thanks for the link! If I can't find a used Y pipe in good shape that is a great backup plan.

With regard to Kalifornia emissions, depending on the tech, it will fail the visual before they even hook it up to the analyzer. I have Hanna skid plates which would make it more difficult to detect, but it's still a risk. However, since I do have a good Toyota front cat now, I could buy that setup on ebay for $300, cut off their cat, and weld on the OEM cat. I know it seems wasteful, but it would probably cost nearly that much to have a new Y pipe made from scratch.

Cheers,

[gray]

The stuff on ebay looks like it was made out of a low grade steel; hard to tell of course from a photo, I sent the seller a question about the steel, etc; will see what they say.

I would think that a custom muffler shop (not one of the chains) could weld up
a Y-pipe for you out of a high grade stainless for not much more than some cheap stuff off of ebay??

You have the cat and the flanges; all they would have to do is get the bends and collector right.

G

[rdublin]

Originally Posted by gray

The stuff on ebay looks like it was made out of a low grade steel; hard to tell of course from a photo, I sent the seller a question about the steel, etc; will see what they say.

I would think that a custom muffler shop (not one of the chains) could weld up
a Y-pipe for you out of a high grade stainless for not much more than some cheap stuff off of ebay??

You have the cat and the flanges; all they would have to do is get the bends and collector right.

G

The photo on the eBay auction is the same as the one on the Bosalna site, thought they are supposedly made by Davidco or somesuch. Please post what you hear back from the vendor.

I'll check with the local muffler shops to see what they quote to make up a new downpipe, though it won't be stainless because I have to weld it to the cat.


Cheers,

[gray]

Originally Posted by rdublin

The photo on the eBay auction is the same as the one on the Bosalna site, thought they are supposedly made by Davidco or somesuch. Please post what you hear back from the vendor.

I'll check with the local muffler shops to see what they quote to make up a new downpipe, though it won't be stainless because I have to weld it to the cat.


Cheers,

The OEM exhaust is all stainless; if you bring your cat and flanges
to a shop that can do it with stainless (if they know how to work with stainless, if not, go somewhere else), they can weld it all up for you, it would actually be better (for you) if they did the entire job.
ie: if you screw it up, you eat it, if they screw it up, they get to
do it again.
g

[gray]

You know, after looking at the inside of the Y-pipe at the collector, I am wondering if the infamous 80 exhaust whistle is maybe produced at this point?
Anyone ever run their 80 with just the Y-pipe, and still hear the whistle??
g

[john_eckels]

http://www.cruiserparts.net/parts/fj80.htm has some CATS new and used. You may have to call or email to see if they are Kalifornia certified

17410-61240
17410-61200 1991-1992 Brand new replacement, Left or Right comes with down pipes. $349
91-92 Used factory Toyota. $250
1993/94 New factory Toyota $399
17401-66090 1995-1997 Brand new replacement catalytic converter, Front $399
18450-66120 1995-1997 Brand new replacement catalytic converter, Rear $249

[landtank]

Originally Posted by gray

You know, after looking at the inside of the Y-pipe at the collector, I am wondering if the infamous 80 exhaust whistle is maybe produced at this point?
Anyone ever run their 80 with just the Y-pipe, and still hear the whistle??
g

I posted that observation in your whistle thread. I don't recall an answer.

[gray]

Roger that; doesn't hurt to ask again I figure.
g

[rdublin]

Originally Posted by gray

The OEM exhaust is all stainless; if you bring your cat and flanges
to a shop that can do it with stainless (if they know how to work with stainless, if not, go somewhere else), they can weld it all up for you, it would actually be better (for you) if they did the entire job.
ie: if you screw it up, you eat it, if they screw it up, they get to
do it again.
g

OEM is stainless?? Mine sure is rusted for being stainless! I know stainless will corrode, but I would have sworn this was mild steel, given its condition. I guess I better go take another look, thanks.

[rdublin]

Originally Posted by gray

You know, after looking at the inside of the Y-pipe at the collector, I am wondering if the infamous 80 exhaust whistle is maybe produced at this point?
Anyone ever run their 80 with just the Y-pipe, and still hear the whistle??
g

My 80 was whistling, which is how I found out it was cracked. I could also feel exhaust puffing out from the Y when I held my hand up there. I was one week away from a trip to Baja, so I welded up what I could (there were cracks going 3/4 of the way around) and packed muffler paste in the slot between the downpipes. The whistle disappeared. The repair held for a while, but I got a P0420 (insufficient cat function) late in the trip and the whistle came back. About three weeks later my front cat grid collapsed driving home from work. I assume it overheated due to unburned fuel reacting in the bottom. I am guessing the front O2 sensor was reading a lean condition due air being sucked in the crack, so the computer was running the engine in a rich condition. I know my mileage was down.

[gray]

Yes,
OEM is entirely stainless.
g

[rtarh2o]

I just removed the engine from my 94, the exhaust seems to be pretty good. Unfortunately I cut the exhaust around the front mud flap. Where is the Y pipe and what does it look like? I am willing to give mine away (if I didn't destroy it) if someone is willing to pay the shipping.
Rusty

[gray]

Originally Posted by rtarh2o

I just removed the engine from my 94, the exhaust seems to be pretty good. Unfortunately I cut the exhaust around the front mud flap. Where is the Y pipe and what does it look like? I am willing to give mine away (if I didn't destroy it) if someone is willing to pay the shipping.
Rusty

The Y-pipe refers to the two exhaust pipes that come down off the
engine, then are joined together to make one slightly larger pipe
that goes a short distance before it goes into the first cat, hence Y designation.
If you cut yours off at the mudflap, it should have been beyond the
Y, but before the first catalytic convertor; correct?

G

[rdublin]

Originally Posted by rtarh2o

I just removed the engine from my 94, the exhaust seems to be pretty good. Unfortunately I cut the exhaust around the front mud flap. Where is the Y pipe and what does it look like? I am willing to give mine away (if I didn't destroy it) if someone is willing to pay the shipping.
Rusty

Rusty,

If you cut it off anywhere south (towards the cat) of the Y joint, I'd be happy to take it off your hands. The Y pipe is just down stream of the exhaust manifold. You can see it if you look through the right front wheel well just behind the tire. The Y is about even with the frame, give or take. Have you removed the exhaust manifold yet?

Cheers,

Rod

[rtarh2o]

The manifolds are off, I cut it between the manifolds and the cat, just around the front mudflap, it was 2 pipes at that point so I probably cut what you needed!
Let me know if you think you can use it.
Rusty

[rdublin]

Originally Posted by rtarh2o

I just removed the engine from my 94, the exhaust seems to be pretty good. Unfortunately I cut the exhaust around the front mud flap. Where is the Y pipe and what does it look like? I am willing to give mine away (if I didn't destroy it) if someone is willing to pay the shipping.
Rusty

Rats! In my excitement I forgot that the 94 has parallel cats (as opposed to series cats post Jan 95) and their Y pipe is downstream of the cats, as opposed to in front of them as in later models. Long story short - you don't have the same parts.

See http://www.sor.com/sor/cat046b.tam?xax=5315 for a good picture.

Thanks anyway!

Rod

[gray]

Roger that; I missed that little point also; duhh
g

[hatfieldcb]

Does anyone have any experience with the aftermarket version of the Y pipe that SOR sells?

[baktasht]

Or you could always go for an upgrade from a trusty IH8MUD vendor
Exhausts : EMSPowered, High Quality, Great Service, Low Prices

[hatfieldcb]

I appreciate what you are doing. Looks like a great product. Just weighing my options. I have to decide if the extra performance is worth the extra expense to me.