2004 Toyota Camry xle 2.4 L 2azfe engine with 136,503 miles with automatic transmission, no trouble codes was scanned on obd2. I noticed a loud noise near the muffler area. After inspection I noticed a small crack on the outer seam spanning about 3 inches. Than upstream after the muffler flange on the turn there is a small hole rusted and broken about the size of a quarter. The rest of the resonator pipe and assembly and cat looks good on all sides. I can't afford the stealership and am looking for a fix that will last maybe a weld, flex tape or something else. What do you guys think I should do in this situation?
The rest of the Camry is running good except for slower acceleration due to the holes I believe. This happened overnight. I did drive over some potholes and a rock kicked up under there I remember. The cat to pipe n assembly, muffler was replaced 4 years ago with after market parts from Napa. I bought the car at 108,000 miles 4 years ago and would like to keep it with all the work put into it. Please help a member out?
The only repair that will last is to weld it. In fact I just had this done on my daily driver where the exhaust needed to be repaired, the shop welded a sleeve over the area that separated. Stay away from the dealer and chain shops - take the car to a good independent exhaust shop, or at least an independent mechanic equipped for welding up exhaust systems.
@chucktobias I found a local shop who does welding. He is booked about a week out always but I've heard nothing but good reviews. The original exhaust work was done 4 years ago. Is this normal for a resonator pipe and muffler to rust out with holes with minimal driving under normal conditions except for potholes? I thought these parts would last much longer even being aftermarket. Also is there a way I can upload some pictures to show all of you guys?
@jimmy2tone How long an exhaust will last depends on the quality of the parts and workmanship, and the environment they're used in. Instructions for pictures and videos are in the topic "READ THIS FIRST - Forum Guide" in the Visitor Info section of the main page.
Agreed with @chucktobias on doing a proper weld is best.
If you want one of the easiest and cheapest fixes, Heavy gauge tinfoil, and screw on hose clamps. I used this for a couple of weeks before I did a welded patch with new coupling on one car, and used it before putting an entire new exhaust on another.
It will greatly deaden the sound, and if it breaks it can help provide some support. Just wrap it numerous times with the heavy gauge tinfoil, for best results. At least 2 clamps of course, but if the damage is very long, just use more.
It will be a little tricky on a corner piece, but can be done.
@nlord Thanks for the tip. What about that metallic cement: https://www.amazon.com/J-B-Weld-37901-Temperature-Resistant/dp/B01IBOBY74?ref_=ast_sto_dp&th=1
Would this work with foil over it and a couple clamps?
@nlord Also what would be a fair price for welding on this job? There is a lot of rust on the flanges which I know many shops will want to to a complete overhaul on my car. Last time it cost me $1,600 + and after 27,000 miles I am in almost the same situation.
@jimmy2tone Yes JB weld is normally good stuff, though I have never tried the high temp version. Walker Muffler cement is another option. Those would likely be better on the crack than the hole, but you can give it a go. Try not to get that stuff on a connection, or it may make it impossible to come off. Worst case though you just cut and weld. Having a friend with a mig welder is very nice for things like this. The tinfoil method will likely not be needed if you use the jb weld or muffler cement, but you can use it until you do that if needed. The cost of a small crack fix can typically be cheap, $50 or less. Pick a method and go for it. Worst case it doesn't work great, and you know how to do it better the next time. If you live in the rust belt like me, the next time won't be long LOL!
Than upstream after the muffler flange on the turn there is a small hole rusted and broken about the size of a quarter. The rest of the resonator pipe and assembly and cat looks good on all sides. I can't afford the stealership and am looking for a fix that will last maybe a weld, flex tape or something else.
You need clean metal to attempt a weld job, and you can't fix rust holes They have durable kinds of tape that you can get at any auto parts store. https://www.autozone.com/emission-control-and-exhaust/exhaust-repair?searchText=Exhaust+tape&redirectUrl=true
@justin-shepherd I've never found those kind of tape or putty exhaust patches to work for very long. They might be OK for a very temporary repair but a more permanent solution like welding is needed for a daily driver. A good exhaust shop can get very creative in cutting out rust and welding in a sleeve or short length of pipe.
@justin-shepherd I'm going to check around and do some research. Only a few shops do welding in my area. Hopefully I can find one who will weld these 2 holes. Usually they want to replace the parts with a 100% markup on the parts plus labor.
Scotty explained cons of rusted exhaust systems and why it's better to get a new one
https://youtu.be/WwOgD1P44hI?t=291
