96 FJZ80 header pipe to 94 exhaust manifolds

[merkproctor]

I never followed up with how my project finished out. I did end up ordering a full exhaust system using the Bosal brand. The '96 down pipes do fit '94 Manifolds. Mine were bent from shipping a touch but I bent them back and they cinched up tight and never did leak. I used a block off plate for the upstream sensor bung and the down stream sensor bung after the post CAT. I ordered 2 Toyota bungs and welded them equal length 8" from the Exhaust manifold. The Bosal system didn't line up well with the rear exhaust mount above the rear axle. I ended up getting a universal mount and bolted to an existing frame threaded hole. They system passed emissions flawlessly, readings were better than I have ever seen it with 194K miles. The truck runs smoother, seems to have a bit more power and no CAT rattles (mostly from less-restriction of old CATs). No check engine lights and the emissions tech never was the wiser for a visual inspection.

View attachment 1377104

Is this the down pipe you used?

MagnaFlow® - Standard Direct Fit Catalytic Converter

 

[inkpot]

With new cats being 3-way technology, you probably could of gotten by with just one. I did.

 

[merkproctor]

With new cats being 3-way technology, you probably could of gotten by with just one. I did.

What down pipe did you use? The Magnaflow 1995+

 

[Beck64]

trolling an old thread...

Basically this is telling me that I can run the 96 exhaust on a 94 and use the inline cats vs. the PAIR of cats, and need to relocate the O2 sensors to fit correctly?

 

[Broski]

trolling an old thread...

Basically this is telling me that I can run the 96 exhaust on a 94 and use the inline cats vs. the PAIR of cats, and need to relocate the O2 sensors to fit correctly?

Yep, I would ditch the second cat and do a cut and turn for better clearance.

 

[xetura]

trolling an old thread...

Basically this is telling me that I can run the 96 exhaust on a 94 and use the inline cats vs. the PAIR of cats, and need to relocate the O2 sensors to fit correctly?

Yeah, the magnaflow downpipe and/or exhaust works fine with a 93-94. You don't need two cats, just one will do since it's newer. The o2 sensors can be relocated to the exhaust manifolds if you remove the PAIR system.