4runner exhaust question

[Jetboy]

I'm sadly due for a new muffler on my 96 4runner. The factory muffler held up well considering it made it to 195k miles. Still sounds fine, but it's rusting through around the spot welds and the emissions folks want a new one.

So I ordered a muffler with pre-bent pipe and flanges attached through rock auto from Bosal. I'm looking at the pipe and notice that the flange is welded about 3/4" back from the end of the muffler pipe - so basically the pipe extends a good 3/4" past the flange. Is this normal? Before I tear apart my DD I'd like to make sure everything is in order so I can get it back in action quickly.

Anyone used a Bosal muffler before? If so, did it fit correctly without modification? I'm hoping it's a quick job. We'll find out tomorrow probably.

Thanks,

jetboy

 

[Brake Weight]

Is there enough room to cut that off and use a coupling to join the two sections together with a couple of U-bolt style clamps? Or is it supposed to mate up with the cat?

 

[Jetboy]

Is there enough room to cut that off and use a coupling to join the two sections together with a couple of U-bolt style clamps? Or is it supposed to mate up with the cat?

It's intended to bolt on exactly as the factory piece would. I can cut off the excess tube if necessary and keep the flange.

I'd be kinda pissed if I have to fab up my own piping and weld it together. I can. I just paid extra for a bolt in unit so I can spend 1hr putting it in instead of an afternoon. If that's the case I'll send it back and just go buy a stand alone muffler and weld it in.

I assume I'll end up cutting off the bolts and welded nuts - the nuts on mine are welded in and I believe they look factory installed. It is the original Toyota muffler so I assume everything else is original.

It basically looks like this:

 

[ken_79-fj40]

It's not uncommon to have the exhaust pipe extend past the flange and slip inside the pipe it's connecting to. I've taken apart lots of Toyota exhausts that were like this. If you live anywhere that they use road salt don't expect more than a couple years out of a Bosal exhaust. Fit is decent but they rust really quick.

 

[Jetboy]

It's not uncommon to have the exhaust pipe extend past the flange and slip inside the pipe it's connecting to. I've taken apart lots of Toyota exhausts that were like this. If you live anywhere that they use road salt don't expect more than a couple years out of a Bosal exhaust. Fit is decent but they rust really quick.

That's not good to hear. I figured if the factory version lasted 195k miles, the aftermarket one should get me 100k more and I'd guess that's the life of this 4runner. Hopefully it won't rust out that quickly. I suppose I get what I pay for...

 

[Jetboy]

I installed the new muffler part this weekend. Fit exactly like the factor piece that came off. I did have to do slight modification though.

For future readers of this, the easiest way to remove the old one is to cut the pipe just behind the muffler. Then remove the tail pipe section with the small piece of muffler pipe still attached. The welded on nuts on the flange are on the bottom side making the bolts nearly impossible to remove. Why? because they are originally assembled before body is put on. With the body off, the bolts are easy from the top. When rusted on and very hard to reach, it's easier to cut the pipe then remove the tail pipe and cut the bolts off and separate the flange on a work bench. (it does require dropping the spare tire - no big deal).

Once you have the tail pipe separated at the flange. Align it with the new muffler section on the bench and bolt it together with the nuts on what tail pipe section (this will bet the top of the mated flanges when assembled). Weld the two nuts on the top. That way you can put the bolts up from the bottom and by doing this on the bench you know it will fit properly. Now the welded nuts are on the tail pipe flange and it's easy to assemble from the bottom!

The rest is very easy. I also swapped the 02 sensor on the bench.

The whole swap took about 1.5 hours of kinda lazy work. Oh, and make sure you get the right exhaust rings. There is a smaller sized set for the manifold collectors.

Just wanted to give an update if someone searches for this down the road. Very easy swap.

The exhaust note is louder by a little bit than stock. I prefer quiet cars, so this wasn't ideal, but it's not so loud that I'm unhappy. Just a little bit louder, and mostly under 1500rpms.