1997 FZJ80 exhaust leak -- ouch ($$$$)!

[051009]

The one I got was the same way. Sorry but I didn't take photos of that stage of the project so I cant show you. My experience is "bolt on" anything exhaust usually needs some modification.

This is back yard red neck advice but I cut mine down with a reciprocating saw flush with the flange surface with a lip to hold the gasket. (not cut down to the gasket mating surface.) If you're not comfortable with that because its easy to mess up take it to someone that knows how to do this stuff. Though they're probably just going to cut it down too. Or weld a new flange on witch would be the best way because it would get everything lined up straight.

May have to just take an angle grinder to the lip of the OEM catback, I just really really hate making permanent modifications to the stock stuff.

Will post updates when I get the replacement order.

Anyone know how much a OEM 2nd cat costs? Probably expensive...

 

[051009]

Just got the replacement cat, same issue, no go. Inner diameter is 2.4" at best.

I see someone once asked the same question in a OEM muffler for sale thread and the seller managed to snap a nice picture and took a nice measurement, inner diameter on the stock piping is 2.75".

See post 3

For Sale - FZJ80 95-97 and FJ80 94-95 OEM Exhaust System with Cats (updated)

1996 fzj80 rust free exhaust system with cats. Two bolts at rear cats are broken. Pulled from a healthy running car that passes emissions. Price $400each system 1993 fj80 perfect condition exhaust system with cats. Same, perfect running car. 93-94 Exhaust system by vubuilt posted Jun 26...

forum.ih8mud.com

 

[lacasd]

Just got the replacement cat, same issue, no go. Inner diameter is 2.4" at best.

I see someone once asked the same question in a OEM muffler for sale thread and the seller managed to snap a nice picture and took a nice measurement, inner diameter on the stock piping is 2.75".

See post 3

For Sale - FZJ80 95-97 and FJ80 94-95 OEM Exhaust System with Cats (updated)

1996 fzj80 rust free exhaust system with cats. Two bolts at rear cats are broken. Pulled from a healthy running car that passes emissions. Price $400each system 1993 fj80 perfect condition exhaust system with cats. Same, perfect running car. 93-94 Exhaust system by vubuilt posted Jun 26...

forum.ih8mud.com

Thanks for this information. I think I may spring for the OEM 2nd cat. $70 difference.

Second Converter - Toyota 18450-66120 | Norwalk Toyota Parts

1995-1997 Toyota Land Cruiser Second Converter 18450-66120

parts.norwalktoyota.com

 

[051009]

Thanks for this information. I think I may spring for the OEM 2nd cat. $70 difference.

Second Converter - Toyota 18450-66120 | Norwalk Toyota Parts

1995-1997 Toyota Land Cruiser Second Converter 18450-66120

parts.norwalktoyota.com

Appreciate the link, that's a good price. I went ahead and ordered it.

 

[051009]

Again thanks, I appreciate the link to Norwalk Toyota. Nothing fits or work as well as Toyota OEM parts.

Here's everything I used to replace *only* the second cat:

Part Number​	Part Name​	Price​	Quantity​	Total​
90917-06043​	Catalytic Converter Gasket​	$10.28​	2​	$20.56​
18450-66120​	Second Converter​	$501.70​	1​	$501.70​
94180-41000​	Suspension Stabilizer Bar Link Nut​	$1.59​	2​	$3.18​
18495-76010​	Retainer Converter​	$16.28​	1​	$16.28​
90080-10204​	Bolt Flange​	$1.13​	2​	$2.26​
90105-10388​	Front Pipe Bolt​	$1.28​	2​	$2.56​

Subtotal: $546.54​

Local Pickup: $3.00​

Tax: $56.02​

Total: $605.56​

Code gone, catalytic converter readiness monitor set, downstream O2 sensor now reading a steady ~0.6-0.7V at cruise. Life is good.

 

[vegasfj40]

Apologies to revive an old thread but did you have issues with getting the 2nd cat to mate up to the rear exhaust pipe? There is a lip on the rear exhaust pipe and the pipe diameter is too large and the Magnaflow 2nd cat's pipe is too small and the exhaust won't fit into it...

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I just experienced this exact problem. Had to return both cats for credit. Going to order oem toyota cats.

 

[jatree]

I just experienced this exact problem. Had to return both cats for credit. Going to order oem toyota cats.

That sucks - this is something I was hoping to do this winter. No way they would fit?

 

[vegasfj40]

That sucks - this is something I was hoping to do this winter. No way they would fit?

No. The inside diameter of the magna flow cat is too small to accept the tailpipe lip. You would have to grind the lip off of the tailpipe side so they would fit flush. I'm going to just replace my rear cat from Toyota and see if that cures my inconsistent P0420 code.

 

[jatree]

No. The inside diameter of the magna flow cat is too small to accept the tailpipe lip. You would have to grind the lip off of the tailpipe side so they would fit flush. I'm going to just replace my rear cat from Toyota and see if that cures my inconsistent P0420 code.

Ah got it good luck. I had a short appearance of a P0420 but it went away in the midst of a lot of EVAP and EGR work I've been doing (new charcoal canister, new evap and fuel hoses, new vacuum hoses, new VSV). However, I'll probably be going down the same road soon with the cats. I have a feeling one or both is partially blocked. Any reason you are replacing just the rear cat? I know some people go from 2 inline to 1 if their state allows.

 

[Right Turn Clyde]

I recently took our '97 in for some exhaust rattles. Rotted out/ready for full replacement was the conclusion from the shop.

I replaced it cat back 3.5yrs ago, using Vibrant 3" resonator and Magnaflow 13646, with aluminized pipe. Pretty frustrated that it's lasted less than 4yrs.

How many have had stainless pipe custom bent? Are results worth the $$$($)?

I assume no one stateside offers a stainless system for the FZJ80?

 

[Red703]

I recently took our '97 in for some exhaust rattles. Rotted out/ready for full replacement was the conclusion from the shop.

I replaced it cat back 3.5yrs ago, using Vibrant 3" resonator and Magnaflow 13646, with aluminized pipe. Pretty frustrated that it's lasted less than 4yrs.

How many have had stainless pipe custom bent? Are results worth the $$$($)?

I assume no one stateside offers a stainless system for the FZJ80?

Land Cruiser Stainless Exhaust

Custom built stainless exhaust for Land Cruisers

www.otramm.com

 

[vegasfj40]

Ah got it good luck. I had a short appearance of a P0420 but it went away in the midst of a lot of EVAP and EGR work I've been doing (new charcoal canister, new evap and fuel hoses, new vacuum hoses, new VSV). However, I'll probably be going down the same road soon with the cats. I have a feeling one or both is partially blocked. Any reason you are replacing just the rear cat? I know some people go from 2 inline to 1 if their state allows.

I am trying to solve my P0420 code and hoping just the rear cat will do it. If not I'll be replacing the front as well. It's 1500 bucks from Toyota so I'm hoping just the rear will fix it. Neither one are clogged.

 

[jatree]

I am trying to solve my P0420 code and hoping just the rear cat will do it. If not I'll be replacing the front as well. It's 1500 bucks from Toyota so I'm hoping just the rear will fix it. Neither one are clogged.

Hope it solves your problems. I had my clogged suspicions confirmed the other day via a backpressure test done thru a small hole in front of the first Cat. So the front is definitely in need of replacing and it was suggested to me do both. The Y-pipes look fine so now the decision is:

​

a) Remove both cats, put a single replacement -- but not sure which one would work and last​

b) Remove both, replace both​

c) Replace both with Magnaflow Y-Pipe + Single Cat -- but considering my Y-pipe is fine, I rather not chuck it​

d) Replace both with Magnaflow Y-pipe + 2 inline Cats --​

​

Doing some reading on here today

Confirm?: Can one universal catalytic converter replace the dual OEM setup? 97 LX

forum.ih8mud.com

Cheap, universal catalytic converters

forum.ih8mud.com

The muffler shop that tested for me was pretty surprised and said they don't see a lot of Toyota cats breaking down. So I also want to figure out why they got clogged in the first place...I haven't had the truck long but not losing oil so maybe running rich and time to do injectors, not sure.

 

[vegasfj40]

Hope it solves your problems. I had my clogged suspicions confirmed the other day via a backpressure test done thru a small hole in front of the first Cat. So the front is definitely in need of replacing and it was suggested to me do both. The Y-pipes look fine so now the decision is:

​

a) Remove both cats, put a single replacement -- but not sure which one would work and last​

b) Remove both, replace both​

c) Replace both with Magnaflow Y-Pipe + Single Cat -- but considering my Y-pipe is fine, I rather not chuck it​

d) Replace both with Magnaflow Y-pipe + 2 inline Cats --​

​

Doing some reading on here today

Confirm?: Can one universal catalytic converter replace the dual OEM setup? 97 LX

forum.ih8mud.com

Cheap, universal catalytic converters

forum.ih8mud.com

The muffler shop that tested for me was pretty surprised and said they don't see a lot of Toyota cats breaking down. So I also want to figure out why they got clogged in the first place...I haven't had the truck long but not losing oil so maybe running rich and time to do injectors, not sure.

I replaced just my rear convertor yesterday and that seems to have solved my P0420 code! My scan tool shows system ready for emission check. The o2 sensors are working as the should.

 

[jatree]

I replaced just my rear convertor yesterday and that seems to have solved my P0420 code! My scan tool shows system ready for emission check. The o2 sensors are working as the should.

Nice! Glad to hear it and you got to use a known good Toyota part.

I elected to go with a single Magnaflow 99006HM to replace both cats. The brick in the front one was completely destroyed, no wonder the high pressure reading (and previous melting of EGR Vacuum Modulator). I only saw the rear from behind and the honeycomb looked normal but I felt better replacing both. No codes and O2 readings look right. I don't know if my scan tool has the Cat Monitor feature will have to check.

I will be doing some reading into possible causes and what components may need attention due to driving with an exhaust restriction for some time. And who knows maybe I can drive up hills now.