In an effort at replacing a broken front pipe for the exhaust on a 94 pickup, I noticed the intermediate pipe / muffler joint was cracked half way around. It is not a major problem yet because the muffler hangs in a way that puts pressure against the gap, and from an emissions standpoint, the associated leak is after the catalytic converter and therefore not a major hazard.

Nonetheless, while I have the exhaust fairly disassembled, I would like to know how I might adequately repair the gap short of having a welder. Is there some kind of patch that would provide an adequate seal if not structural reinforcement? Would I be better off taking the piece to a metal / muffler shop and having a proper weld?

 

Take it to a muffler shop, theyll probably weld it back up pretty cheap

shem

 

Really the best way to fix that is to have it welded. With it already out, it'll take someone 10 mins or less. It'll be cheap. If you see the metal in the area is starting to corrode and get thin though, it may be time to replace it altogether before long.
I had a crack in the same spot on my truck and got it welded but it's cracking again about a year later. I'm looking into a new exhaust

 

Given labor costs, you may be better off just replacing it.

Also, look around to see why it broke there. Of course it might be due to some manufacturing defect, but too often I see people make changes in how the exhaust is supported and it causes breaks like this. Make sure all those original rubber hangers are in place.

 

Has to be welded to have a prayer of being a lasting repair. An exhaust shop could probably buzz a new muffler under there for <$100.

 

I guess I'm lucky. Not long after I bought my 87 4Runner, back in 95, the muffler did the same thing. Cracked around the inlet pipe. I took it a "name brand" muffler shop (beep-beep MC etc...). Just recently, it did it again. I know, right? Cheap muffler and install, yeah? I mean really, only 20 some years? Be real...

Anywho, I took it to the local "name brand" shop. They looked in their records, and lo and behold! There was my 4Runner. They replaced the muffler for free this time, and inspected the rest, end-to-end. Took about 20 or 30 minutes total. Nothing like having a lifetime warranty. Now I'm counting the years down until I have to take it in again. 20 or 30 years passes so quickly...

Take it to a muffler shop, and have them replace it with an OEM muffler. Look how long the old one lasted, after all. And as I said, the lifetime warranty makes it worth the initial cost, eventually. At least it did with mine!

Good luck!
Pat☺