Toyota Tacoma Muffler Replacement 1995 – 2004 Easy Fix!


So I’m going to show you how to replace a
muffler on a Toyota Tacoma in just a second. But first, I want to see how exactly a muffler
works. So we’re going to open this up. This is the part that goes up to the engine,
and then this is the part that decreases the sound – the volume of the exhaust. So something in here is muffling the exhaust,
and then the rest of the fumes go out the end. So I couldn’t cut it all the way open. There are two bands of metal right here holding
it all intact and I ran out of SawZall blades. This is where the exhaust comes in from the
engine, and it goes through this tube into this first chamber. And now I imagine, I’m not an exhaust expert,
but the sound echos around inside of this chamber and then it can go out some of these
other tubes like this one, and then back into this chamber through another tube. And so the sound stays in here, echoing around
itself while the fumes and the exhaust can eventually end up going out of this hole and
all the way out the back of the truck. So for the muffler, I did open this section
right here and it looks like it’s just full of more air. So it’s just one more chamber inside of the
muffler itself. But still, pretty cool and pretty inexpensive
for what it accomplishes. Now that that’s over, let’s get started with
the actual repair. [Intro] So my truck’s had a problem for a while with
the muffler. The muffler’s been slowly going out more and
more, burning a hole through the bed of my truck. I’ll show you. So this right here, we have the bed-liner
here and then another layer of bed-liner underneath. This truck is pretty old – it’s a 1998. But the muffler has been letting exhaust come
up through the bed of the truck and rusting away the metal. But this isn’t how a truck should look. Now normally I wouldn’t really care. The truck does sound a little bit louder than
most. I’ll let you listen to that now. And all the exhaust fumes are coming up through
this hole right now. Since the garage door is closed, I’m going
to go turn it off. But the problem is there is a lot of heat
coming up through that hole as well, since exhaust is hot. It’s literally burning gas fumes. So normally I’ve put this slab of granite
over the top of the hole to kind of keep the heat below the truck, but this weekend I have
to pack a bunch of boxes, and boxes…cardboard, catches fire. So I have to fix this problem before the weekend. Luckily I do have the replacement muffler
right here and it does seem like a pretty easy fix. I have a clamp. Basically I just have to cut off the old muffler,
slip this over the top of it, and then clamp this down tight on the old pipe. There are a couple of hangers on this new
muffler right here, right here, and another one right there. And these go inside of a little rubber piece
which I’ll show you right now. The new tail pipe hanger would just slip up
through this same little hole in the rubber piece What I’m going to use to cut the tail pipe
off with is a skill saw, so it’s got a fine metal blade on it right now that can cut through
metal. This section right here you can see how it
flexes up and out. This is what fits over the other tailpipe. So we have about this much room to work with,
so the cut doesn’t need to be exact, but I do want to leave as much metal as possible
intact on the old tailpipe so that I don’t need to add anything later. And this is the part that we’re going to be
cutting. So right here we just have the muffler and
then the tailpipe goes out the back of the truck. And I’m going to cut it…we have this little
bracket right here along this side, but I’m going to cut it as close to the muffler body
as possible so I have all of this extra pipe to work with. I think I might need to re-cut it about here
just so it fits. But just to err on the side of safety I’m
going to cut it pretty deep. Back down on the rest of this pipe, we’ve
got the catalytic converter over here, and then another bracket. But I shouldn’t have to touch these because
this pipe will just fit right into the new muffler down here. Now we are on the underside of the truck and
here are the two little rubber things supporting the muffler. Found it easiest if I just grab the bottom
of the rubber with this and press on the top of this metal thing with the other end of
this. Alright, the muffler is now dropped out from
underneath, and the last part we have left is this one. So basically I’m going to grab the bottom
of the rubber with this and press the metal with the other side of these pliers. So getting this out would have been a lot
easier if I would have dropped the spare tire out from underneath the truck. This is what it sounds like with no muffler
at all. Everything is just coming out of that one
little pipe right there. Now it’s time to attach the new one…after
I turn the truck off again. Whoever’s idea it was to stick an unremovable
sticker on a super hot tailpipe…it’s pretty ridiculous. So it turns out we have a problem. What I thought was the little expansion thing
at the bottom of the tailpipe, which is this guy right here, see how it like widens up
a little bit to fit over another piece of pipe? I was wrong that it was going to fit over
the stock pipe from the truck. What this is meant for, this is what I think
anyway, there’s supposed to be a piece of pipe that sits down in the middle and fits
all the way down in there. I’m probably going to have to hammer that
in because it fits pretty tight, and then this stops it from going all the way in. And then the other piece of pipe slips over
the top of this. And then I have the two clamps on the end
that I’ll show you in a second that clamp down on either side of the pipe to keep the
exhaust from coming out. I did drop the spare tire down a little bit. You go in through a little hole right here
underneath the tailgate, and then you can turn a little knob and that drops the tire
down. Kind of a pain. I think my bumper’s bent a little bit so the
hole’s not there anymore. That was a pain. But right now, since the tire can sway a little
bit, I should have enough room to slip the new exhaust pipe in without too many problems. So now I have this little pipe inside of the
muffler. This pipe right here is a 2 and 1/8 inner
diameter. I’ll try to link these down in the video description,
if not, I’m sure you can try and get them at a local hardware store. And then I have the clamp right here that’s
going to make sure everything sits tight. I decided to put my bolts on the top because
this is the part that’s going to be resting up underneath the truck bed and this is the
part that’s going down to the ground, and so the less parts hanging down means less
things to connect with rocks and stuff when I’m going off-road. Also since I didn’t factor in that the pipe
wasn’t going to fit inside of the other pipe, now I have to re-cut the stock pipe on my
truck so it’s a little bit shorter and it’ll fit over that connection. So what I’ve done right now is I’ve taken
the new tailpipe, stuck it up inside this bracket so I know exactly where it needs to
sit on this end. And then I can just lift this up until it
touches this other pipe right here and see where I need to cut it so it will slip on
over that other end. So according to this, when I lift it up I’m
going to want the new cut, since it’s fitting inside, about here. And that should work. Nailed it. Now I have pulled this exhaust away from that
rubber on the end so that I can line up this tailpipe a little easier. Hopefully it will slide in easy enough. It’s so close. So what I’m doing right now is just bending
the lip of this pipe a tiny bit all the way around the outside, hoping to just get it
wide enough to start slipping that pipe inside. So I bent this pipe in just a tiny bit, and
this pipe out just a tiny bit so now they’re lined up pretty tight. And now I just need to pound this in the rest
of the way. If I get a rubber mallet on the end of this
it should go in well enough, as long as I pound on the seam. Alright, that’s about as good as we’re going
to get. So I got that by twisting the muffler back
and forth and just wedging it super tight inside of this pipe. So I’ll put another clamp here in a second. Got both the rubber brackets back in so there’s
just like one little curve right here and then it’s straight for a while and then it
curves back down. Basically I took these all the way off, put
this through it and then snapped it over the top of it with that rubber mallet just hitting
the rubber right here. And that put the metal tube back through the
rubber hole. Kind of the same deal on this one. Since the bottom of the truck is down here,
I don’t want these bolts sticking out catching on rocks and stuff as I’m driving around. So I’ll put this clamp with the bolts facing
up. Alright, so let’s see what it sounds like
really quick. Now all the exhaust is coming out here. Got this rubber thing connected. No sounds coming from this hole, that’s great,
or from the muffler itself. Pretty excited about that. Now since we’re in a garage, I’m going to
go ahead and turn my truck off. So it looks like everything went smoothly
on my end. The muffler’s now in place, the truck is much
quieter and now I can transport boxes without them catching on fire. So let’s say you have a small hole in your
muffler and you don’t want to replace the whole thing. So first of all, a shop quoted me about $230
to replace this on my truck. My truck has 240,000 miles on it and I’m going
to sell it in a couple months anyway, so I didn’t want to pay that much to have a shop
do it and I knew that the part itself was around $89 give or take, and then I could
install it myself. There’s a little bit of extra parts, you know,
I took clamps and stuff. That put me right around $100. Still saved quite a few dollars. But if I just had a small hole in my tailpipe
or even in the muffler body itself, there is this heat tape that has kind of like…not
like an epoxy…I’ll link it down in the video description below, but you can take it, put
it on water, put it over the metal. It’s hard enough to sit over that tailpipe
and even the heat won’t disturb it. So look into that if you have just a small
hole because it will save you a lot of time and money. That tape is pretty cheap. I’ll link that in the video description. So yeah, I hope this project helped you out
a little bit, whether you’re trying to replace the muffler in your own truck, or you just
like watching a process like this. I thought it was a fun project myself. Thanks a ton for watching. Hit that subscribe button if you enjoy projects
like this. I plan on doing more and more on this channel,
but we’ll see how it goes. Thanks a ton for watching and I’ll see you
around.

About the Author: Michael Flood

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