I have a few exhaust leaks I want to fix. All of the leaks are on the down pipe between the header and the cat. I replaced the gaskets at the header end and they are already leaking after a few days of driving. Also there are a lot of cracks in the downpipe/ front pipe, some were attempted to be fixed by the last owner by welding on top of the cracks. they just welded on the surface w/ out much penetration. Should I pull the pipe off and try to fix their welds and the new cracks, just replace the pipe or save up and do a full new exhaust?

 

if you know how to weld, weld it and save up for the exhaust system you want. if not, get headers and a downpipe and go for it

 

I had similar issues...





Looks like it's more common than I though.

I had a buddy of mine weld her back up, but now I think the welds have broken lose and it's leaking again. I'm just waiting it out to get a header for it.

 

Installing a flex coupling should help a lot. It should be as close to the front as possible.

Also fab up a brace to support the exhaust where it comes close to the tranny bell housing. Toyota has a brace there from the factory, that helps keep the engine/tranny and the exhaust all moving together. Something like this:


Also check for a broken engine or tranny mount, that can cause excessive engine and tranny movement.

 

had the same problem buddy.
mine cracked in half exactly as in the picture..
took it to the local muffler guy and he replaced all the tubing from the header back with 2.25 inch and a big magnaflow can slash tipped under the cab.
sounds amazing.! even better for 120 bucks and an hour

 

Here's a good example of proper flex coupling placement:
https://www.yotatech.com/50673125-post22.html