Best option for Rattling Muffler Replacement

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I recently picked up a '97 LX450 and have been using this board extensively to get up to speed on it. It's got 247K miles on it and the PO definitely wheeled it, so it's got some bumps, bruises, and "trail modifications". But I bought it to wheel anyway, and have no plans to restore it to anything close to factory condition. I also bought at the absolute peak of the 80 Series Market, so I have no illusions of ever getting back what I put into this rig. If all I do is get my money's worth in fun on the trail over the years, I'll be perfectly satisfied.


So far I've had it checked out by a local Land Cruiser specialist, and they said it's in overall good mechanical condition for its age. I had all fluids replaced, and installed new front brake pads. I replaced the rear sway bar bushings, mounting brackets, and end links. I installed a Delta VS rear Panhard lift bracket. There are a few other worn out parts on my list that I will be replacing, and I'm sure there will be more added to the list. But it's basically trail-worthy in its current state. I fully expect to have stuff fail on me, or get broken immediately. But I should at least make it to the trailhead.


One item that I know needs to be replaced sooner rather than later is the muffler. I've got a crazy rattle coming from the muffler. Sounds like there's something loose inside it when I hit it with a rubber mallet. I took it to a local muffler shop, that is run by a really knowledgeable and straightforward guy. He does great work for everybody - be it a soccer mom's minivan or a custom hot rod. He concurred with my assessment that the muffler is junk. Looks like the PO replaced the stock unit with something aftermarket. Not sure of the brand, but it appears to have 2.25" pipe on both the inlet and outlet side. The rest of the system, both fore and aft of the muffler, is 2.5". The flanges are still there, on both sides, so they had to adapt the 2.25" up to 2.5" between the muffler and the flanges. I assume the OEM system is all 2.5", but I could be wrong. (Still learning Land Cruisers).


The muffler shop guy suggested that I just purchase the OEM Toyota center muffler, which would likely bolt right in. Of course, I'm not enamored with the prospect of spending $500 - $600 on an OEM muffler - at least that's what it appears to cost if I purchased it from McGeorge with tax and shipping. Not that I couldn't swing it, but I am willing to compromise and could certainly put the money to use elsewhere. I'd probably lean towards having him put in an aftermarket muffler as long as it isn't too loud. I don't need it to be whisper quiet. But if the aftermarket parts use 2" pipe, I wouldn't want that to hurt performance. Not that these rigs are rippers, but I sure don't want to lose what little grunt I've got.


If you were me, with my stated goal of “function-first”, and a desire to keep costs reasonable, what muffler would you go with?
 
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Joined
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Bosal from RockAuto.

Coat it with 2-3 coats of hi-heat 1000°F clear paint prior to installing.
 
Joined
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Thanks. Checked Rock Auto, and not seeing any Bosal exhaust parts at all. There was a "Famous Brand" cat-back system, but out of stock. (Also shows it uses 2.25" piping.) There are also some low-cost / off-brand mufflers, but not Bosal/Borla.

Sounds like you had something else in mind than what I'm seeing on RA. I'll keep looking.
 
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I believe BRExhaust is what Bosal is now. It's a Magnaflow company. The supply chain sucks right now, so it might be hard to find. There's one on Ebay for $273. Looks sold out about everywhere else.
 
Joined
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Attached is the Mud link to my parts list when I did mine.

I looked also and did not see Bosal anyplace.

 
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I took it to a local muffler shop, that is run by a really knowledgeable and straightforward guy.

Sounds like you got a good exhaust guy. Replace it with oem if the rest of the exhaust is oem.
 

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I recently picked up a '97 LX450 and have been using this board extensively to get up to speed on it. It's got 247K miles on it and the PO definitely wheeled it, so it's got some bumps, bruises, and "trail modifications". But I bought it to wheel anyway, and have no plans to restore it to anything close to factory condition. I also bought at the absolute peak of the 80 Series Market, so I have no illusions of ever getting back what I put into this rig. If all I do is get my money's worth in fun on the trail over the years, I'll be perfectly satisfied.


So far I've had it checked out by a local Land Cruiser specialist, and they said it's in overall good mechanical condition for its age. I had all fluids replaced, and installed new front brake pads. I replaced the rear sway bar bushings, mounting brackets, and end links. I installed a Delta VS rear Panhard lift bracket. There are a few other worn out parts on my list that I will be replacing, and I'm sure there will be more added to the list. But it's basically trail-worthy in its current state. I fully expect to have stuff fail on me, or get broken immediately. But I should at least make it to the trailhead.


One item that I know needs to be replaced sooner rather than later is the muffler. I've got a crazy rattle coming from the muffler. Sounds like there's something loose inside it when I hit it with a rubber mallet. I took it to a local muffler shop, that is run by a really knowledgeable and straightforward guy. He does great work for everybody - be it a soccer mom's minivan or a custom hot rod. He concurred with my assessment that the muffler is junk. Looks like the PO replaced the stock unit with something aftermarket. Not sure of the brand, but it appears to have 2.25" pipe on both the inlet and outlet side. The rest of the system, both fore and aft of the muffler, is 2.5". The flanges are still there, on both sides, so they had to adapt the 2.25" up to 2.5" between the muffler and the flanges. I assume the OEM system is all 2.5", but I could be wrong. (Still learning Land Cruisers).


The muffler shop guy suggested that I just purchase the OEM Toyota center muffler, which would likely bolt right in. Of course, I'm not enamored with the prospect of spending $500 - $600 on an OEM muffler - at least that's what it appears to cost if I purchased it from McGeorge with tax and shipping. Not that I couldn't swing it, but I am willing to compromise and could certainly put the money to use elsewhere. I'd probably lean towards having him put in an aftermarket muffler as long as it isn't too loud. I don't need it to be whisper quiet. But if the aftermarket parts use 2" pipe, I wouldn't want that to hurt performance. Not that these rigs are rippers, but I sure don't want to lose what little grunt I've got.


If you were me, with my stated goal of “function-first”, and a desire to keep costs reasonable, what muffler would you go with?



 

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