Magnaflow 2nd catalytic converter fitment issue

[051009]

Just wondering how many of you have tried installing the CA compliant Magnaflow 2nd cat (PN 447217) and encountered issues?

There is a lip on the OEM rear exhaust section and the Magnaflow cat pipe is too small and won't fit over the lip.

What does everyone suggest?

 

[TomH]

I couldn't get mine tight so I ended up using two gaskets as a "temporary" fix.

 

[retlaw]

I cut most of the lip off and also used two gaskets.

 

[051009]

So much for a "direct fit" solution.

 

[eaphelps]

I started this cat replacement job on my 1996 80-series and ran into the same issue with the magnaflows. Anyone else have a good solution for a tight fit on the flange?

 

[Malleus]

Cut the pipe short. If you took it to a muffler shop, that's exactly what you'd get.

That "lip" is nothing more than the pipe exending through the flange. The OEM cat was designed such that the pipe slipped into the cat to provide support during assembly. The bolts do all that is needed there. The gasket provides all the sealing that is required. The extra pipe into the cat is not needed; the cat-to-cat connection doesn't have it.

Yes, Magnaflow should have caught that, but since no one is complaining to them, they aren't likely to get right on that to fix it.

 

[eaphelps]

Success! Cut the pipe lip on the rear exhaust section short with an oscillating tool and metal cutting blade so I could mate the flanges. Next step was finding usable gaskets. The ones included with the magnaflow cat were hot garbage -- much too thin to fill the recess in the flange and also too large in diameter. I had trouble finding OEM Toyota exhaust gaskets. Everything was leaking terribly with the magnaflow gaskets. After much research, found these gaskets that were available at the local autoparts stores and all seems solid with no leaks. Engine sounds much better with the new cats and new O2 sensors in. Hopefully check engine light stays off and no leaks long term.

MAHLE Catalytic Converter Gasket | MAE #F7572 fit perfect for the y-pipe flange to exhaust manifold. Says it fits 1996 Toyota Land Cruiser.
https://www.oreillyauto.com/detail/...=MAHLE+Catalytic+Converter+Gasket+|+MAE+F7572

Felpro #61039 is a perfect fit for the flange recesses on both sides of the magnaflow rear catalytic converter. Site says it does not fit 1996 Toyota Land Cruiser but matches up dimensionally perfectly to the OEM gasket I took out and fits solid in the magnaflow cat flange recess.
Advance Auto Parts - Down for Maintenance - https://shop.advanceautoparts.com/p/FelproExhaust+Pipe+Flange+Gasket61039/20680656-p

 

[Batameez]

Funny enough, the BRExhaust catback system has that same lip and has the same fitment issue with a Magnaflow cat. You'd think being made by the same parent company they thought it through.