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Yesterday my exhaust pipe broke and of course it was difficult not to notice with my truck suddenly sounding like a motorcycle
I am wondering how possible it may be to replace this myself. I already have some of replacement gaskets where the pipe bolts to the manifold. Would I also want to replace the o2 sensors while I'm at it? Where is a good source for a new pipe between the manifold and cat?
Some of the nuts seem fairly well corroded and might need pblaster and a pipe wrench .. a good source for replacement hardware?
You are gonna have a lot of fun getting that O2 sensor out. Looks like PB Blaster time. Let it soak in. Apply it a few times over several days, then grab the nut with Vice-Grips, and go for the gustor. Try NOT to break the studs, although they ARE replaceable. The nuts are readily available at you local nut dealer
As old as it looks, I would definitely replace the O2 sensor, but that's just me. Up to you entirely.
If it were mine
I'd take it to a muffler shop and have them weld it back up and call it good.
rather than opening a can of worms.
IF they are any good they can do it on the truck.
Last edited by 87-4runner; 03-08-2021 at 12:08 PM.
The first question is: Why did it break in the first place? I agree that getting it welded at a muffler shop is a smart move, but if you don't address the root cause it's just going to break again.
On the rusted nuts, yes one option is PB Blaster applied several times a day across *several* days before attempted to turn the nuts. And then I'd use a torch to expand them a bit.
But if you really want to save the studs, I'd consider splitting the nuts rather than even attempting to turn them loose. Replacing a stud that twists off can be a major PITA and is not without risk. If you don't have a nut-splitter and don't want to buy one, then you can also use a dremel tool to cut the nuts off.
I don't know much about the 22re (and you didn't give year/model/body), but if I've identified the correct pipe it is available from (where else?) Toyota. https://parts.lakelandtoyota.com/sho...rimLevel=18379 There are several different parts (depending on body style), so call a dealer WITH YOUR VIN and see if you can get a part number.
Removing those nuts will be no picnic. While I've never worked through quite that much rust, I think Blueman's suggestion of a nut-splitter is the right way for you. They don't cost much. https://www.napaonline.com/en/p/BK_7769259
If it were mine
I'd take it to a muffler shop and have them weld it back up and call it good.
rather than opening a can of worms.
IF they are any good they can do it on the truck.
Yes it's a muffler shop job. Independent muffler shops around here have reasonable prices.
of course forgot to mention the truck is a base model pickup (6ft bed)
looks like a new third-party pipe would run around $250
went to the muffler shop, they and was quoted somewhere proud of $350, which seems pretty reasonable but told them I might try dismantling it first as I wouldn't mind cracking some nuts and also because one of the three manifold studs are broken and would add at least another $150 to the labor
figure I might put a 1/8" bore then try an extractor after heating the manifold with a torch
as far as reusing the old pipe, I was told a new weld would just likely break again and it looks like a weld repair was already done in the spot it broke
the root cause is shown in the pic with the broken hanger that was this way for some months ..
That's a stupid high price!!!
it will take them 30 minutes to prep and weld it up... even if it's an hour it shouldn't be much over $100 bucks. Find a different shop or go back and tell them you'll let them do it for $100 .
Last edited by 87-4runner; 03-08-2021 at 03:05 PM.
That whole pipe on a 92 22RE RWD non-California is around $93 plus tax and shipping. I just looked at a few prices on the net.
Go to AP Emissions, and search the catalog for the correct part number for your truck. You can search Walker catalog too. No way in hell I would pay $350 for that work. That's a big rip job.
Independent shop that I get work done uses AP stuff, and Eastern Catalytic is part of AP now too. The owner has been running it since the 60's, and he said he won't deal with Walker any longer because a lot of their stuff won't make it past warranty.
fwiw, i replaced my entire exhaust on my 22re, including a davico cat, for less than $400 delivered. i did the entire removal and installation in my driveway. front pipe, cat, hangers, insulators, rear pipe/muffler, gaskets.
They don't normally break. As the OP pointed out, there was abnormal stress because of a failed hanger in the system. Also, given the pictures of previous welding, there's been some creative work done on this exhaust system.
Seems like the OP is on track now, getting either Toyota or Walker new parts. I know from searching for my '87, some of the Toyota exhaust parts are no longer available, such as the exhaust from cat back.
thought it might also be worth looking into all the parts other than the catalytic converter and got to wondering about the benefit of replacing the muffler and other pipe sections
maybe a matter of longevity as opposed to better performance? Though I have been unsatisfied lately with the appearance of the tail pipe and have thought about some heat resistant paint ..
looking into the parts from advance auto, it looks like the front pipe and outlet muffler assembly would total not much more than $200 with a Walker discount code
there are other outlet options but think I found the one of the right length with the CA downstream O2 sensor port;
the hangars on the muffler appear somewhat different -- crooked rather than straight with a ball end ..
the originally failed hanger behind the cat also does not seem to be present, but maybe I can hose clamp that in place until I have it welded.
03-08-2021, 09:26 AM
