Walker aftermarket exhaust system (problem) [solved]

[c_j]

Well, I splurged and ordered a complete aftermarket exhaust system by Walker Exhaust.

Unfortunately I ran into a problem with the length of the system. Something is about 8" too long. I have contacted Walker and and will wait for their reply. Here are the details:

Picture of Walker's Exhaust System e-Catalog page:

terc_exhaust.gif

I ordered these items for my 1986 Toyota Tercel Wagon; 4WD; 1.5L; Manual Transmission:
(in order - front to back)

Code: Select all

1x 31320 Gasket
1x 44899 Front Pipe
1x 31320 Gasket
2x 35725 Insulator
1x 15682 Catalytic Convertor
1x 31332 Gasket
1x 46691 Intermediate Pipe
2x 35352 Insulator
2x 35352 Insulator
1x 35343 1.75" Clamp
1x 18305 Muffler
2x 35352 Insulator
1x 35594 Spout

Here are the old and new systems side-by-side. I have lined up the front flanges on the front pipes; and the hangers and over-axle bend on the intermediate pipe. They may not look in line (due to parallax error), but they are. Notice how there is no way that the convertor will fit between the pipes:

old_and_new_exhaust.JPG

*note that a previous owner had welded in a couple of straight sections of pipe on the old system. One where the convertor was, and one just ahead of the muffler (which moved the muffler back of where it should be).

I have test-fitted the two pipes and this is what it looks like on the car:

converter_not_going_to_fit.JPG

The space is 8.5" and the convertor is 16.75". If you use Walker's EPA Convertor-only e-Catalog, then it gives two part numbers for "direct-fit" convertors, the 15682 (16.75") and the 16360 (12.5").

There are two ways to fix this dilemma: shorter converter or shorter pipe

• .
• On the shorter convertor: I just sold a complete used exhaust system to dlb with a really short converter, so I know they exist. (dlb, if you are reading this and don't mind measuring yours, I'd be interested to know the length)
• On the shorter pipe: The first 9" of the intermediate pipe is a straight run. Also, looking at the picture above, notice that the underfloor heat shield is shaped like a convertor and is quite long. So I think the longer convertor is probably what it originally had, so there should be a shorter intermediate pipe that goes with the longer convertor.

One other problem is that there is no hanger welded to the convertor. Typically there should be a bar welded perpendicular right behind the front flange of the catalytic convertor. It should be pre-bent in a certain shape have a knob on either end for accepting 2x 35725 insulators as pictured in the catalog page above. Funny how the insulators are available, but there is nothing to attach them to.

[rer233]

The metal hanger at the front of the cat is a seperate part- you have to re-use the old one or order a new one. Good luck!

[c_j]

The metal hanger at the front of the cat is a seperate part- you have to re-use the old one or order a new one. Good luck!

Can you tell me who makes this part separately? There wasn't one listed in the Walker catalog, and there was only half of one left on my old system.

[rer233]

Got my last one from toyota (prob 12-13 years ago- may now be NLA.) Good luck.

[scrapz253]

why do you need a cat?

[c_j]

Got my last one from toyota (prob 12-13 years ago- may now be NLA.) Good luck.

Thanks, I will check the stealership for this part if I can't find a used one.

why do you need a cat?

Honestly I don't need a cat. Right now I've got a rich-fuel problem (which I think is about to be remedied by an engine swap), and the exhaust smell has been absolutely horrible (getting comments from people who get stuck driving behind me). When ordering the system, it just seemed easy to order all the parts so it bolts together nicely and I wouldn't have to do any welding or modification (ya right!), plus it would make the exhaust smell more bearable.

[keith]

The California cars had a three way cat that was about 4" shorter than the federal cat. The federal cat had an air intake port sticking out of it. It looks like neither of the Walker cats are a direct fit, maybe they were supposed to be a direct fit for their systems.

The original muffler included the intermediate pipe welded to the muffler and came in two sizes, one 4" shorter (federal) than the other (CA muffler).

Your new muffler layout is backwards in your picture. The Walker online catalog should have the measurements for each piece. I would check the length of the intermediate pipe and see if the one they sent you matches. If it doesn't, they should send you a replacement. If the measurement matches, they may work with you on getting their dimensions corrected and make you a new pipe, or not. If not, then you could take the intermediate pipe to a muffler shop and have the appropriate length cut off at the cat end and have a new flange welded on. Shouldn't be more than $20.

I just went through a similar incident with Bosal for our 97 Accord. I ordered a new muffler and intermediate pipe. I didn't really need the intermediate pipe at this time but I thought, I'm under there, why not. The intermediate pipe fit OK but one bend radius was a little too sharp, so it hit the heat shield at that bend. I looked it up, the diagrams showed the correct bend radius, they had a picture and the bend radius looked right in the picture, so I e-mailed them pictures of my OEM pipe and their replacement pipe showing the incorrect bend. They said they checked their inventory and all the other pipes they had were correct so I sent the first one back and they sent me a replacement. Guess what? They ended up sending me a refund and the OEM pipe is now in the car.

[c_j]

The California cars had a three way cat that was about 4" shorter than the federal cat. The federal cat had an air intake port sticking out of it.

The cat I was supplied is the longest one listed and does have the air intake port.

Your new muffler layout is backwards in your picture.

I disagree. In the picture, you can barely make out the hanger at the back driver-side of the new muffler. The old muffler has the hanger in the same position, and has the same part number stamped in it as the new one. Plus I have installed these Walker mufflers before and the longer end is the tailpipe. The old muffler in the picture has had the tailpipe cut off and an extension welded on the inlet (by a previous owner; it was also hung with yellow poly rope and a plastic cable tie).

The Walker online catalog should have the measurements for each piece.

Should is right. They only list the cat lengths as far as I can tell. I did contact Walker and they said:

The 46691 is a straight line length of 66" and the 46692 is a straight line length of 62". The measurement is from one end to the other straight line without following the bends.

I would need something around 59" to make this cat fit.

I would check the length of the intermediate pipe and see if the one they sent you matches.

My 46691 pipe measures 68" (68.5" if you count the little bit of pipe that sticks past the flange), so about 2 inches longer than it is supposed to be.

If not, then you could take the intermediate pipe to a muffler shop and have the appropriate length cut off at the cat end and have a new flange welded on. Shouldn't be more than $20.

I may end up doing that.

For completeness, here is what Walker Techline had to say about my fitment question:

The 46691 would be correct for the Canadian built model with a manual transmission. IF it is Canadian built with an Auto Trans you would use the 46692. If it is not a Canadian built it would use the 45851. The 18305 would be correct only if it is not built with California emissions.

I will ask them about the length of the 45851 pipe now and see what they say.

[Jarf]

Once upon a time, many many moons ago, I got an a/m system and ran into the same problems as you.
In the end, IIRC, the problem was that some of the parts were for auto trans equipped car and the rest for standard, they had different length pipes.
My supplier kept ordering pipes until we made it work but I don't remember the details now.
I think(?) we ended up with the auto spec pipe to solve the problem but it was over 10 yrs ago, details are rather fuzzy now.

Since that fiasco, I have only used OEM stuff (besides it lasts a LOT longer and fits better)
Hope you sort it all out.

[c_j]

Once upon a time, many many moons ago, I got an a/m system and ran into the same problems as you.
In the end, IIRC, the problem was that some of the parts were for auto trans equipped car and the rest for standard, they had different length pipes.
My supplier kept ordering pipes until we made it work but I don't remember the details now.
I think(?) we ended up with the auto spec pipe to solve the problem but it was over 10 yrs ago, details are rather fuzzy now.

Since that fiasco, I have only used OEM stuff (besides it lasts a LOT longer and fits better)
Hope you sort it all out.

Interesting.

Well Walker got back to me on the U.S. (non-Canadian) intermediate pipe:

The 45851 has a straight line length of 60".

So this is my pipe! The one that I need to make it all work!

.....except I'm told it is obsolete.

So, back to shortening the 68" pipe down to 60". I will try that tomorrow.

Marking this thread [solved]. The solution (for the Walker brand exhaust) is to order the parts list in the first post and shorten the #46691 intermediate pipe. I did another test fit, and made allowances for the gaskets, and I will be cutting off 8.625".

[c_j]

And now the pics (annotated after posting):
supplied pipe is about 8" too long

IMG_2652.JPG

this is an air-gap pipe (pipe within a pipe for insulation purposes and for pipes ahead of the catalytic converter - to help with faster converter light-off)
pipe was slotted with disc grinder and cutoff blade

IMG_2653.JPG

gaps cleaned and widened enough so the pipe can be shrunk. using vise grips to hold inner pipe away from the side where work is being done

IMG_2654.JPG

i was going to cheat and use a hydraulic hose ferrule crimper, but it would have took taken an extra day to do the job, so the low-tech method was an old muffler clamp to crimp it down

IMG_2655.JPG

view of the crimped pipe

IMG_2656.JPG

side view of the crimped pipe

IMG_2658.JPG

comparison of the stock crimped pipe with flange and my version

IMG_2659.JPG

alternate view of same

IMG_2660.JPG

gouged out the slots into v-grooves with 1/4" thick grinding wheel

IMG_2662.JPG

after welding up the slots and grinding flat

IMG_2664.JPG

cutting off the factory welded flange

IMG_2663.JPG

grinding the weld off the factory welded flange (then pound out the short piece of pipe that remains)

IMG_2668.JPG

install everything for test-fit and tack-weld in place

IMG_2671.JPG

after a bit of welding and a whole lot of grinding - making sure there are no perforations in the welds

IMG_2674.JPG

paranoia weld on the end of the pipe- just in case exhaust gas could sneak into the gap between the inner and outer pipe, as the outer pipe is not sealed (I assume to allow for air expansion)

IMG_2675.JPG

[c_j]

remove stickers with heat gun (boy are those stickers heat resistant)

IMG_2676.JPG

after cleaning pipes with Sherwin-Williams strong solvent cleaner (to remove oil/grease/residue), painted with minimum 5 light coats of Plastikote Hot Paint
also in view is the hard-to-get catalytic converter bracket that was gifted to me and refurbished

IMG_2677.JPG

IMG_2678.JPG

another view of the white paint job

IMG_2682.JPG

and another

IMG_2687.JPG

and yet another

IMG_2688.JPG

[keith]

Good job. Did you do all the welding yourself?

[ARCHINSTL]

Great documentation!
You won't regret the heat-resistant paint! I used Rust-Oleum flat black HR spray when I installed Goldie's Bosal last year - and nary a speck of rust!
I would have rather used white, as you did, but I painted the system when I got the Bosal back in late 2010, and that was all Home Depot had, and I didn't know the R-O actually came in colors.
The paint "rested" for almost two years, as my J-B Weld repairs on the old system held up that long.
I didn't paint the cat, as it was in use in the old system. It will be interesting to see if your cat retains its paint.
Tom M.

[dlb]

i've never heard of painting an exhaust system. do you use any primer or just go to town with high temp rust paint?