2002 Tacoma Exhaust Newb Question

[duke000088]

My girlfriend's 2002 Tacoma needs a new muffler. I'd like to try to change it out myself to save us some $$$. However, I've never touched exhaust before and I'm a relative novice on my XJ (tune-ups, ball joints, brakes).

The tail pipe, muffler, and exhaust pipe are all one welded unit. The exhaust pipe has a flange that bolts to a flange on the catalytic converter. The flange joint is totally corroded - I don't think I can unbolt it.

To me, the obvious plan of attack is to:
1. Cut the cat just forward of the flange (leaving a straight end)
2. Remove the old muffler assembly
3. Install the new and CUT the NEW muffler's flange off (another straighty)
4. Join the two cut ends with a union
5. Clamp it all up.

Is that a ghetto fix? I'd like to "do it right"... what would a muffler shop do? Should I have a shop weld the union and pipes together instead of clamping it up? What is the best method to cut exhaust pipe on a vehicle... I don't have access to a torch or any welding equipment.

 

[GrimmJeeper]

cut it with a sawzall, and put band clamps on it they call em eazy-seal exhaust clamps. i would weld the whole thing together, but clamps would be good enough till you can get it to a shop to have it welded. i dunno how common it is out there but out here in CA its very common to have your cat stolen, they give big money for em at recycling yards. the toyotas are especially vulnerable because of the bolt together flange. its not to hard to do the job, just make sure you get the cat and the muffler on facing the right direction, it DOES make a difference

 

[duke000088]

Good deal - thanks for the input.

Haven't had much trouble with stolen cats - YET... knock on wood.

 

[duke000088]

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