My truck (89 22re 4runner) exhaust is all welded except for the manifold/downpipe connection. Below are a couple of pictures showing the crack in the exhaust that has developed. I bought the truck with no cat and am not wanting one because we do not get tested in Kansas.






For a fix I am thinking of ordering,



and because my exhaust has no flanges to bolt it to and is all welded I will cut this new part and use a 1.75 inner diameter 4 inch pipe to slide over the two exhaust pipes and clamp that at either end.

Does this look like the way to go or does someone have a better idea?


Thanks

 

unbolt they system enough to get at the crack with a welder?

you could also chop the exhaust and either re-weld together or use a bolt-on/clamping splice connector to reinstall

 

I want to know what was moving so much that it cracked??

Not enough support ??

I am betting you can`t weld or don`t have access to a welder.

What ever works to get it done.

 

I am thinking it cracked because it is braced at the engine and the tranny without any flex pipe. The engine is going to rock a little and put stress on the exhaust piping.

 

possibly....it's also 25yrs old, gets heat cycled regularly, and is located fairly close to the header - eventually the 16ga metal will give up and crack....i'd say you got a pretty good run.

if you're worried about the rigidity, then there's another reason to chop it for repair and reattach with exhaust flex-pipe connector.

 

As long as its rubber mounted at the back on hangers and is able to move a little like from the factory, then a flex pipe isnt needed. The exhaust will move with the engine movement.

 

I was tired when looking I thought this was something you had just installed not long ago.Then it had cracked all ready

My stuff pretty much gets new exhaust system after 3 winters if not sooner.

 

Just ordered the exhaust piece pictured earlier and a 4 inch 1.75 id pipe and two clamps. Hope it goes together well.

 

Now I looked at the rest of the exhaust and after measuring the piping the section after the muffler is smaller (about a .25 inch) than the rest of the exhaust before it. How much horsepower do you think that is costing me?

 

Under normal driving conditions......none. Under wide open throttle on a dyno...it will go from a 116hp beast to a 115hp dog.

 

I've had mine crack there twice. I think it is because of the heat expansion and the mount by the tranny... the expanded pipe has nowhere to go and develops cracks.

To allow for expansion, I just keep that mount loose by the tranny. I have the folded metal mount as shown in your picture of the new exhaust. I just put the mount in place with no bolt in it. Ever since I did that I no longer develop cracks.