Replacing the Muffler

......and it's already time for a new muffler. My Van's been sitting for a while, again, and finally got a new battery for it and reregistered. When I did drive it, I noticed it was a little louder than usual. I went to check the muffler and, yup, the arm that attaches to one of the rubber hangers is already rusted off the muffler itself leaving a nice hole right there. The Van now sounds like a ricer. O'Reilly has a Walker Sound FX that's made from aluminized steel for a decent price. I wonder if anybody has had any luck with those. The muffler I have now is welded onto the pipe it came with. I wonder if I'd be ok cutting it off or just buy a new pipe and use a clamp. I figure since I'd be able to use a clamp, it'd be easier to change the muffler if it goes bad again. I only paid around $100 for the new catalytic converter. I hope it's holding up ok too. So is it pretty common for aftermarket mufflers to only last this long?

When I lived up north that's the kind of lifetime I would expect out of an after market exhaust system.

What did you install in 2006? Was it the Bosal cat back unit? Tim says that Toyota still offers lifetime warranty on the exhaust - most times though I think Toyota needs to install the unit to be able to take advantage of the warranty. It's pretty pricey too... I think around $200 or $300 just for the muffler.

Mine needs a muffler as well & I think my exhaust is all original... I saw that $60 walker. It's tempting... I don't want to remove the 'silencer' on mine & do the whole cat back without the silencer.. Even with the hole the muffler its not that loud & living in Texas I think the Walker would be fine.

But after a while living up north I ended up going heavy duty with the best stainless I could get. If you have a good muffler shop in your area you might want to have them look at it... sometimes a good exhaust shop will do you better than internet shopping.

I don't know much about exhaust systems, but I get the feeling that they need to be able to drain water correctly or they will rust where water collects. Sometimes holes are drilled in those spots - I think my station wagon has a drain hole like that.. But I think a lot of it is angling the pipes so they just drain out the back... You might want to check with the guys that installed you exhaust.

The 84s didn't have that silencer (resonator). Just the cat and the muffler. I installed the exhaust system myself. It was fairly easy after cutting the bolts on the old catalytic converter. Luckily, it's not so obnoxiously loud. Still quieter than those fart cannons on ricers.

So to my surprise and delight I was able to purchase a brand new muffler and exhaust pipe unit from Toyota for $200. According to the dealership there is only one other left in USA inventory so act fast.
Attachment 3802

Next to my surprise is that the old muffler combo was easily unbolted from the catalytic converter. Finally a project that was going well! OR NOT... I can not figure out how to get it out of the car. I got the 2 bolts off and and all the suspension rubber parts off but no matter how I twist it, move it, push it, it gets jammed up on the rear drivetrain / random pipe / brake line. I could just cut the old out one, but I would have the same issue getting the new unit back in.

I did search the forums and even looked through the repair manual with no luck finding anything about how to properly remove/ install the muffler unit.

You will likely need to jack the van from the body to increase the distance between the rear axle and the body. There are 2 jack points, one on each side (low hanging spot on the front side of each rear wheel well). If you only have one jack, jack it from the differential and put your jack stands under those jack points, then lower the diff (let it hang). As always, when jacking a vehicle, be careful and don't take chances. Tim

I've got to do this soon I think as well. I'm really interested in how this goes for you. What part # did you use when you got from toyota?

Rat, the muffler assy for yours & Lateral's van is 17405-73120. Better hurry........only one left :wnk:. Tim

Nice score! I've contacted dealers all over the country trying to get a new cat back for my van with no luck. Hope the install goes well once you get the extra clearance sorted out.

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Originally Posted by timsrv

You will likely need to jack the van from the body to increase the distance between the rear axle and the body. There are 2 jack points, one on each side (low hanging spot on the front side of each rear wheel well). If you only have one jack, jack it from the differential and put your jack stands under those jack points, then lower the diff (let it hang). As always, when jacking a vehicle, be careful and don't take chances. Tim

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Since I already had all the bands and bolts off, I was able to jack it up on the drivers side back only and pull the old muffler right out! So easy!

Thanks Tim!

I went to the dealer on Saturday and the parts guy pulled up 3 of them-
1 for a 4YEC 2WD 86' auto and 2 for 4YEC 2WD 87'-88' auto, I was actually looking for on for my 3YEU 2WD auto Townace and/or my 4YEC 4WD 87' manual, but he said it wouldn't fit either??:?:

sorry I forgot to get the part numbers even though I asked when I first got there.

There are different mufflers for different years and trims of the van. You should see the one for my 89 cargo van. It's got 2 mufflers on a single pipe. Supposedly I got the last one of those. Here's a picture from under the van (muffler installed).

http://i8.photobucket.com/albums/a23...y/IMG_2442.jpg

So if OEM mufflers are no longer available, can any muffler shop do a custom job?
What about catalytic converters? Are they all tailor made to fit specific vehicles and their exhaust output?

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Originally Posted by trestlehed

So if OEM mufflers are no longer available, can any muffler shop do a custom job?
What about catalytic converters? Are they all tailor made to fit specific vehicles and their exhaust output?

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Yes, and in many cases this makes more sense. At least in states other than CA (perhaps there too). Personally I just like bolt-on factory parts, but it will likely cost less to just pay a muffler shop to "fab up" a new pipe and put a standard universal muffler on. The weld shop guys are amazing (at least at the shops I've used). They can shape a pipe and knock these things out very fast. If a new cat is required they just grab a universal one for the correct diameter pipe and weld it on (most of these guys weld everything).

My only gripe with the guy I use is "he welds everything"........and when I say everything, well I mean everything. He doesn't stock the special bungs for Toyota o2 sensors or flanges for bolting to a cat. Unless you tell him otherwise he'll take your old o2 sensor, drill a hole in the pipe, and weld the sensor right to the pipe. I like being able to remove sensors when they fail, so I started stocking my own mounting bungs. When I take him a job, I hand him those parts and he welds them on. He does nice work, he's fast, and he's cheap. As for my vans, I usually replace my own mufflers (when available from Toyota), but have him fab up stuff for my other vehicles. Tim

To pass CA smog, you will need a CARB approved catalytic converter now. Mostly, this means you'll pay about twice what a generic one would cost.

Thanks to the clowns running our state, my Mazda 3 has 3 cats...

Went thru CA smog song and dance in october.Summit Racing has a great replacement for $100....Worked for me, passed smog with flying colors.good luck!

Metro areas will generally have a good muffler shop that does custom work. Here in Buffalo, NY , we have a ''Mufflerman'' that has a good reputation. My 86 2wd had the cat removed and parts bouncing around inside the muffler. They installed a new cat and stainless steel exhaust and muffler for about $450.

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Originally Posted by timsrv

My only gripe with the guy I use is "he welds everything"........and when I say everything, well I mean everything. Tim

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....you guys are right,,, was trying to find an intermediate pipe,, nothing came up. ...anywhere!


It was only the muffler that needed changing,,but of course it was welded on to the pipe :no: ,, thought I had found an easy way round that.

It turned out to be the luckiest day of my life...... I crawled under with my trusty 20,000rpm disc cutter, something I've used in my trade over ~30 years,,,never had an accident.....till today :?:

......almost done the cut,, the blade catches,, hits something,, shoots at my arm,, blade breaks,, gnarles in my t-shirt sleeve,, totally jammed in the cloth,,,a shearing feel in my skin:no::no: ...when I finally untangle the blade,,I pull my shirt off,,thinking th'worst,, to find that the skin was broken,,a 3'' line,, but not enough for bleed, or bleed-out. I am a lucky lucky man.... the workshop's a half hour from -anywhere- :dizzy::dizzy:


....managed to carry on and get the muffler replaced after all that, but sometimes it's not worth saving the buck. :doh: :doh:

Yes, those things can be dangerous. Glad you're okay. I was working in a machine shop, when a guy (seasoned machinist) was revving one of those 20k rpm die grinders with a fiberglass reinforced cut-off wheel in it. Evidently it picked up a vibration and for some stupid reason he held it wide open (bench level). Well, the wheel exploded and one of the pieces went right through his coveralls and into his nut sack :no:. He kept it together well enough to just walk out of the shop, get in his car and drive to the hospital. Didn't say a word to anybody until after he came back and the super jacked him up as to why he left........I worked there for another 5 years and he would still get teased occasionally (things like that never get old when it comes to joking around). In the end, no permanent physical damage, but I'm sure he wishes he'd taken his lumps for an unexplained absence. Tim

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...yah, same thing I was using. If there's one thing I know, if yer feel -any- vibration,, shut down immediatly,, there's something wrong with the disc.

In all my 30 years of using those things I've never broken a blade.
No wonder I spent more than a week looking for alternatives before climbing under there,,,as they say in the boat trade, 'sometimes free is too much:no:

Yeah, if I can't bolt-on I just take it to the muffler shop. Years ago I would buy pipe, clamps, mufflers and cut/fab as required. I've even shaped pipe by cutting little wedges out, bending, then welding shut (a lot of work for a sub-standard job). Nothing like having the right equipment. Every time I take a job to the muffler guy and watch him run his special benders, welders, etc, I have no doubt I did the right thing. Something that would cost me hrs of heartache can be completed in just a few minutes by somebody that does it for a living (and has the correct equipment). The other thing is price. Those guys buy everything in bulk, and quite often the end price they charge you is very comparable to the price you'd pay for just the individual components..........not to mention the multiple trips to the parts store and the busted knuckles :yes:. Tim

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Originally Posted by timsrv

Rat, the muffler assy for yours & Lateral's van is 17405-73120. Better hurry........only one left..

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Poked around couple days ago, guess I wasn't quick enough, Toyota saying part# 17405-73120 is NLA....

I am seriously thinking of doing this: https://www.youtube.com/watch?v=grPaTbljVvw when my muffler rusts through.

Just did my entire exhaust with some reused pipe from a different van, catalytic converter from rock auto and a welder. Had to jack ip the rear and take off the spare. It was one welded piece from end to end. Of course the spare mounts broke and created another project...

Hello. Does anyone have a recommendation for a replacement muffler for my 1989 Cargo (RWD). There's a Walker (18411 I think), but I'm not sure that it fits my van. Thanks.

I just replaced mine with one from rock auto and it was a direct fit.

Thanks. I found A-1 brand pipe and muffler from a place called Baltimore Auto Supply (BAS). Hope they work.

To Timsrv - A question about the double muffler on one exhaust. Does it look anything like this one?

https://www.thewrenchmonkey.ca/produ.../bosal/284977/

Also, have you noticed any difference in sound or performance?

I used an OEM Toyota muffler on mine, and yes, it came as an assembly like the one in your link (appears to have 2 mufflers). Van is quiet, but not any more so than other rigs I have with only the one muffler. Toyota may have put it there for some other reason, but if so, I have no idea why. If the front one were ever to develop a hole and I couldn't get a new OE one to replace it with, I wouldn't hesitate to cut it off and replace that section with a straight pipe. I believe the sound is muffled through the rear one only. Tim

Thanks for the feedback, I just placed an order and will let you know how it goes.

So no such luck on the muffler, the website called a day later to say they did not have the item in stock even though they had several listed on their site. Same thing happened with an OEM Toyota dealer website. Looks like I'm stuck with the one I got. I patched it using some 26 gauge duct and sheet metal screws so it is quieter for now.

Just take it to an exhaust shop. I like the independent guys (not the big chains). Some of these guys are awesome. The guy I use can throw an entire system together and weld everything together in about 45 minutes. Price is very reasonable to boot. It sounds like you just need a "cat back" exhaust made up. Most shops can do that in about 1/2 hr and if they're honest it should be very affordable. Good luck. Tim

Hey guys, Thanks for the helpful ideas here - My Masterace came with a poorly constructed straight exhaust with no muffler. I want to add a muffler and saw part Sir Goofy mentioned ( https://www.thewrenchmonkey.ca/produ.../bosal/284977/ ) Do you think this will fit on my Masterace or am i better off following your advise and getting a shop to fab something up? If i go down the shop root how do i know what muffler to request etc? Any help would be greatly appreciated - Thanks

Ste

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Originally Posted by micah202

I crawled under with my trusty 20,000rpm disc cutter, something I've used in my trade over ~30 years,,,never had an accident.....till today :?:

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In the motorsport business we call that tool the "death wheel",:LOL2: I personally try to stay away from these things and in the rare cases where I cannot find an alternative I get in an armor and the part better be on a bench clamped solid in a vise and it better be an air tool! Electric? No Way!!!!:no:

Yah, used them 'wheels of death' in boat repairs for many years, usually not the luxury of being at a benchvise! Got pretty handy with them,, very fine cuts, shaping etc. Got a bit complacent over the years,, still shake my head when I think how close I came, if it wasn't for the bottom edge of my t-shirt sleeve, I'd be 15 pounds(one arm) lighter. :dizzy:

Quote:

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Originally Posted by brit_ste

Hey guys, Thanks for the helpful ideas here - My Masterace came with a poorly constructed straight exhaust with no muffler. I want to add a muffler and saw part Sir Goofy mentioned ( https://www.thewrenchmonkey.ca/produ.../bosal/284977/ ) Do you think this will fit on my Masterace or am i better off following your advise and getting a shop to fab something up? If i go down the shop root how do i know what muffler to request etc? Any help would be greatly appreciated - Thanks
Ste

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In Vancouver, you might try VAP Auto parts for an actual muffler, then take it to a shop for installation, hangers, etc. You'd save a lot on the muffler itself that way, VAP are amazing.
Otherwise, you'd be relying on whatever amcustom shop has that fits, should work out okay,,, just get a couple of quotes first.

I've got some parts in Vancouver, if you need.

The first muffler in line is called a "resonator", in the Mini community one of the first Mod we did was called the "one ball" (guess what the two mufflers side by side look like from the back :wnk:) where a resonactomy was performed for the gain in weight and a couple HPs at no cost in sound! Guess these resonator are there for regulation reasons in some countries or states.

Quote:

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Originally Posted by micah202

In Vancouver, you might try VAP Auto parts for an actual muffler, then take it to a shop for installation, hangers, etc. You'd save a lot on the muffler itself that way, VAP are amazing.
Otherwise, you'd be relying on whatever amcustom shop has that fits, should work out okay,,, just get a couple of quotes first.

I've got some parts in Vancouver, if you need.

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Thanks for your reply and advice micah - Will have to work out what size i need then go get one at VAP. Regarding parts you don't happen to have a Power Steering Pump for a 2C-T do you? I tried the guys out at http://mustang.bc.c but no luck and i'm waiting to hear back from Rocky Mountain.

Thanks again.

Stephen

Double check for proper fitment-

https://www.ebay.co.uk/itm/POWER-STE...8AAOSws65Tpsvz

JDM

Quote:

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Originally Posted by brit_ste

Thanks for your reply and advice micah - Will have to work out what size i need then go get one at VAP. Regarding parts you don't happen to have a Power Steering Pump for a 2C-T do you? I tried the guys out at http://mustang.bc.c but no luck and i'm waiting to hear back from Rocky Mountain.

Thanks again.

Stephen

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...sorry no power steering gear here.
VAP should have info about stock parts.

Just don't climb under there with a disc cutter,,, a desperate move,,tempting to the devil,,, definitely not worth it. 😈

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Originally Posted by JDM VANMAN

Double check for proper fitment-

https://www.ebay.co.uk/itm/POWER-STE...8AAOSws65Tpsvz

JDM

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Wowww, on eBay uk,, but comes from Emirates! 42uk pounds for shipping! :dizzy: